Khantex Fashions Limited has been established in 2018 but in this short span of time, it has built trust and confidence for its customers by innovation and dynamic production process. The factory has a wonderful combination of knit and woven product making in the sewing line that very few factories in Bangladesh can do.
They have expertise in both woven and knit sewing production so that no order will be left only to lack of capacity.
Why the idea to combine knit and woven production line?
The global apparel business is in the downtrend where some retailers are closing their shops just to minimize their cost. Brands are looking for cheaper options and new product lines to attract customers.
But the RMG sector in Bangladesh sometimes is not able to reduce the product price due to limitations in raw materials that needed to import. The myth of cheap labor is now history in Bangladesh after a 51% wage hike at the end of last year.
So to survive in the business, many factories are taking new innovations that can help the sore business. Khantex Fashions Limited started its sewing line for the making of both knit and woven products. This will help to grab all the product categories that the concern brands sale in their shops.
Humayun Kabir Salim, Managing Director, Khantex Fashions Limited said Textile Today, “We don’t want to miss any opportunity to grow in the business. Our aim to combine both the sewing line to create expertise in both product lines so that operators will not sit idle during dull season. Both the operators from Knit and woven can be familiar other than their own product.”
Status of sewing line
Khantex Fashions Limited set 12 knit sewing line and 6 for woven in the same production floor so that operators and workers can be familiar with both production lines. This helps the knit and woven operators to exchange views and knowledge as well as to understand the difference between both the line processes.
As per efficiency record, it is found that operators who are working only for a knit product can get efficiency 58% whereas woven operator has 55% and those operators who are doing both knit and woven product have efficiency 50%.
Rashidul Hasan, Manager IE, Khantex Fashions Limited informed Textile Today, “We have 4 months skill evolution for the multi-skill senior operators and then provide them special incentive based on performance.”
Advantages to combine the knit and woven sewing line
Not to keep unturned any opportunity: Every retailer has its own special product that makes them unique and dynamic from the competitor. Besides, core product they also keep some products that can be sold as accessories or additional parts for the core product line.
Suppose if knit is the core product for a brand then they have an additional product like bottom to have a good combination of set in the shop. Having the expertise in both product categories any manufacturer can get extra miles to maximize their business.
“When we see brands have some big volumes in one category and small in others then we take both of the products. This helps us sharing profit between both product types. On the other hand, buyers also become happy to keep all the goods in one production unit that reduces their extra workload to place somewhere else,” said Humayun Kabir Salim.
Creating expertise: Multi-functional skill is considered as a robust and exceptional quality that assist to stay ahead in the profession. But in general, Bangladeshi workers are not wellbeing to be multifunctional due to lack of training and guidance.
Realizing the matter, Khantex started to provide training for developing expertise in the Knit and woven sewing line by exchanging operators. Primarily operators get slow improvement in the new machine, product and process but eventually, they could manage to cop up and develop expertise.
Khantex already has started to implement the Traffic light system which is the most effective inspection tool used to reduce defect generation at source.
“Quality is becoming a vital key to the successful growth of a company. Reworks in the garment industry are a common problem that hampers the smooth production rate. Rework is a vital issue for poor quality products and low production rates. Stitching operations (with respect to cutting and finishing) need high skill as well as quality work, because of difficulty associated with repairing of products sewed with wrong specifications. To overcome this problem, Khantex is adopting the Traffic Light System to meet quality requirements.” said Head of Quality.
The 5s System is under developed to make maintaining the workplace in good condition a visual process.
Rashidul Hasan said, “To exchange knit and woven operators and make them familiar for both of the products require special guidance. Just training is not enough to build expertise rather helping them to work in the sewing machine so that they become skilled. In this regard, we are flexible to meet production targets until they get enough time.”
Challenges to combine the both knit and woven sewing line
Knit operators are weaker than woven operators: Khantex makes woven bottom and those operators work for woven bottom they have more expertise than knit operators.
Because the knit product has less sewing process and it does not require multiple operations than that of woven products. Woven products have many critical sewing processes as well as plenty of machines so usually, operators of the woven unit always ahead in the workplace.
Knit product creates more dust than that of woven: Due to construction of fabric knit produces fiber dust during production in the sewing line. The operational dust may not possible to clean right when it is created and so it remains in the atmosphere until all the sewing line gets to stop.
On the contrary, the woven line is cleaner and less dust producer. The operation for knit and woven on the same floor is more challenging because of flying dust and to keep the product clean particularly for woven items.
Md. Kafil Uddin, General Manager- Operation, Khantex Fashions Limited said, “We realized the problem of dust that created from knit sewing line and containing woven products. So, our next plan is to separate both the product line but the exchange of operator will be continuing.”
To summarize it can be opined that the idea of combination for both knit and woven sewing line is unique for Bangladesh, and this can be an example for other manufacturers to follow.