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Fabric Manufacturing (Knitting & Weaving) Industry Best Practices

Sustainable micro dust cleaning process is a new initiative of Masco Knitting

Bangladesh is one of the largest garments exporting countries in the world where Masco is playing a leading role in the knit garment that started export from July 2001. It is a vertical set up of the knit composite factory with all in-house facility and modern machinery run by dynamic manpower to provide the best possible services.

Masco knitting Team
Figure 1: Tanmoy Chowdhury, Sr. Manager (Knitting) (2nd row, from left 4th in standing) with Team Masco knitting.

Recently Textile Today research team visited the unit and found Masco knitting unit as an industry leader in the sector with a wide range of products to a diverse portfolio of clients.

Location and structure

Masco knitting located at Kendua, Kanchan, Rupgonj, Narayangonj built in a beautiful green landscape layout with a shade structure. It has interior functionality for proper ventilation, environmental efficiency model and appropriate work safety design.

A total of 6 acres of land projected for the factory where 159367 Square feet of shade is for production space, grey fabric and yarn store.

Employing local people

A human hand can develop a country if employment opportunity and comprehensive training are available. Keeping it in mind MA Sabur, Chairman, Masco Group established the Masco Knitting at Kendua, Kanchan, Rupgonj, Narayangonj. So that people of his birthplace can get a job and grow as skilled manpower. Around 50% of its employee hired by local people who were completely raw hand before joining.

Tanmoy Chowdhury, Sr. Manager (Knitting) said, “We find the people of this place unemployed and they were not engaged in any productive work. Masco Knitting gave them job and training as well. Now they are solvent enough to run their family.”

Modern circular knitting machines  

Masco Knitting has arranged a collection of circular and rib-knit machines backed by advanced software to meet the demand of time, and this collection of machines is being continually upgraded.

It is equipped with circular knitting machines from the renowned brand such as Fukuhara- Japan (QTY 50), KEUMYONG – Korea (QTY 24), LISKY – Taiwan (QTY 22) Mayer & Cie – Germany (QTY 4), PAILUNG – Taiwan (QTY 15), SANTONI –Italy (QTY 16), Jinhar – Taiwan (QTY 9). The company has a total of 140 knitting machines and 5 Inspection Machine.

Masco fabric production Jan-July 2019
Figure 2: Category wise fabric production for the year of January – July 2019.

The unit is also designed with a capacity of 1200 tons of fabric in a month. The range knitted fabric they make as below –

Composition covered 100% – cotton, viscose, modal, polyester, tencel, linen, Acrylic, bamboo, wool, milk-
blended-cvc, pc, poly-viscose, cotton viscose, poly-cotton viscose, linen excel,
linen cotton, linen poly, cotton els etc.
Single jersey & derivatives Single jersey, single lacoste, double lacoste, polo pique,2 thread terry,
all type of three thread fleece, heavy jersey, plaitted jersey, mesh,
Honey comb, all derivatives with elasthan, All type of single jersey design fabrics.
Rib & interlock designs Basic rib, different type of drop needle rib with and without elesthan, Waffel, mesh,
flat back rib, milano rib, bonded rib, Cord rib, honeycomb, Basic interlock,
ottoman design, different type of mesh, pontiroma, etc.
Yarn-dyed detail All types of yd of S/J & rib both feeder stripe & Engineering Stripe.
Yarn type Card, Comb, Comb comact, Slub, Vortex, Rotor, Lurex Filament yarn, Nepy yarn,
Inject yarn, siro, Nylon & polyester Filament all type of Grey mélange,
100% cotton melange, Air covered yarn.

Continuous Improvement Process (CIP)

Working to continuous improvement is a primary and number one way for the reduction of waste in the forms of cost, time and defects. Masco applies this process in its knitting unit to improve efficiency as formal practice and as an informal set of guidelines.

This is focused on increasing the effectiveness and efficiency of the unit to fulfill its policy and objectives. ATM Mahbubul Alam Chowdhury, Executive director, Masco Group is the mentor to perform CIP.

CIP activities improved below areas –

  • Set off (one type of fabric fault)- 28 % reduced
  • Elastane out and elastane cotton (fabrics fault of ELS fabrics) -80 % rejection reduced
Masco Production increased ratio
Figure 3: Production increased ratio by training and motivation.

To make the CIP program more effective Masco provides various training and learning programs as well as engage the employee in the development activities to meet organizational objectives.

Sustainability approach

Incorporating sustainability into the supply chain is becoming a key priority for many textile and apparel companies. Masco knit also has incorporated various approaches to enhance their levels of sustainable supply chain management.

The monitoring body for the sustainability has been formed in the unit with the aim of ensuring that the working policies and decisions are focused not only towards the protection of the environment but also towards minimization of waste generation and optimum resource consumption.

Flying dust for production floor – In the knitting process cotton micro dust generates major health hazard for the people who are working inside. Cotton micro dust is causing chronic coughs and sometimes even bronchitis to the workers.

To reduce health hazard from cotton micro dust Masco knit uses a centrifugal fan that sucks all the dust from the production floor and in an air tunnel process comes to a small water tank that built in the ground. Flying cotton micro dust is never allowed to release to the outer atmosphere.

The idea of a centrifugal fan to link it with a water tank is the brainchild of ATM Mahbubul Alam Chowdhury, Executive director, Masco Group, said Tanmoy Chowdhury. The cleaning process system can keep the environment cool and sustainable.

Short details of micro dust cleaning process –    

  • Total number of centrifugal fans in knitting floor 56
  • Duct net cleaned twice/day
  • Duct tank dust (waste cotton lint) cleaned twice a week
  • Duct tank cotton dust is used as natural fertilizer after processing
  • Duct tank water drained out twice a week
Masco Knit centrifugal fan
Figure 4: The centrifugal fan works to sucks cotton micro dust from the production floor and dumps in a water tank at the end.

Strong R&D department

In a global industrial landscape, products are getting changed fast continually with new design and features. This is necessary as well due to the fierce competition and the evolving preferences of consumers. So, the Masco knitting R&D team involved in innovation with the acquisition of new machinery.

“We are a leading supplier for circular knitting production in Bangladesh. Our basic product is baby ware so previously we had a focus on very basic fabric but now our products are diversifying towards the high end designed fabric by our skill R&D team. At present we have various categories of fabric in design and color that can easily attract the customer,” Said Tanmoy Chowdhury, Sr. Manager (Knitting).

Masco R&D team made fabric
Figure 5: Masco R&D team makes a strong range of fabric in dramatic décor.

Management information system

Masco Group has a strong software development team that is working for continuous process development to implement less paperwork. By applying Management Information System (MIS)- a digital process- decision making, coordination, control and analysis can be done more effectively. Use of MIS enables Masco knit to monitor all kinds of daily routine, direction and instruction.

MIS reduces paperwork in the unit as well as a commitment to nature for sustainability. This is also introducing the modern information technology in the floor to a commitment to build a digital Bangladesh.

Reward and incentive

Rewards and incentives in the workplace have benefits for both employees and employers. When an employee is recognized for the performance and productivity then job satisfaction will get higher in the organization. Masco knitting started practicing the workplace rewards and incentives for every month.

Management evaluates the efficiency and skill of the operators in different categories and then declare the name for the month. Through these good practice employers and workers enjoy a positive and productive work environment.

Masco Knit best performer names
Figure 6: The name of the best performer for a month is declared and displayed so that others can get inspiration.

Masco knit wants to be world-class fabric manufacturer through innovations in products and business methods that add value to customers and meet global standards in quality, customer service and human resource management.

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