Tuesday, July 23, 2013

Sweater Manufacturing Project

Sweater Project

How to start a sweater manufacturing project? What docs are required? What about machinery and their price? How much area does it require? How much manpower? How much salary? What is the total cost of the project? What is the expected productivity and profit? Let us go through the following article that might be helpful to find the answers. In this article we shall be able to find a-z of a sweater project of 800 hand driven flat knitting machine. The project discussed here is Bangladesh based. This series of article will be helpful to the merchandisers involved in sweater merchandising to learn a -z of a sweater project.

List of required license/document

01
Trade License
02
Verified Memorandum Copy
03
IRC with pass book
04
IRC Recommend
05
ERC with pass book
06
TIN
07
Certificate of Incorporation
08
Investment Board Certificate
09
Project Feasibility Report
10
Factory License
11
BGMEA Registration
12
Fire License
13
Fire Policy
14
EPB Registration
15
Factory Insurance
16
General Bond
17
Factory Layout
18
Bond license customs
19
Bond license BGMEA
20
Bond Specimen Signature
21
Environment Certificate
22
Chamber Certificate
23
Boiler Registration
24
Group Insurance
25
Electricity permission
26
Gas Connection
27
WASA Permission
28
Telephone Connection

Required Area Calculation

Description
Quantity
Required area
01. Knitting section                                               3g
150 sets
30,000 sft
5g
250 sets
12g
400 sets
02. Knitting distribution and inspection chamber

2,000 sft
03. Winding section
16 sets
3,000 sft
04. Dial linking section                                         5g
45 sets
8,000 sft
                                                                   6g
15 sets
                                                                  8g
80 sets
                                                                14g
150 sets
                                                                16g
50 sets
05. Overlock section

800 sft
06. Zipper tuck section

800 sft
07. Linking distribution and inspection chamber

2,000 sft
08. Trimming, mending & continue section

4,500 sft
09. Washing section
3 sets
3,000 sft
10. Hydro extractor section
2 sets
11. Dryer section
4 sets
12. Washing goods dumping

13. Boiler section
2 sets
700 sft
14. Light checking section                                       38"
4 sets
600 sft
                                                                   40"
4 sets
15. Iron section
35 pcs
2,500 sft
16. Iron inspection and label sewing section

100 sft
17. Ware house

4,000 sft
18. Office

1,800 sft
19. P.q.c. final check & finishing section

2,000 sft
20. Sample section

600 sft
21. Generator section

500 sft
22. Doctor's room & child care room

200 sft
23. Pump house

600 sft
24. Workshop

200 sft
25. Toilet

1,800 sft
Total

69,700 sft

Sweater Machinery List

Sl
Description
Quantity
Unit Price
Amount
1
Hand Driven Flat Knitting Machine
150 Sets
$  300.00
$  45,000.00

(Needle Bed 36")                                     3g

Origin : China
2
Hand Driven Flat Knitting Machine
250 Sets
$  290.00
$  72,500.00

(Needle Bed 36")                                     5g

Origin : China
3
Flat Knitting Machine
250 Sets
$  145.00
$  36,250.00

(Needle Bed 36")                                    7g

With Standard Accessories

Origin : China
4
Hand Driven Flat Knitting Machine




Model: Mn Type (Needle Bed 36")              12g
320 Sets
$  290.00
$  92,800.00

(Needle Bed 42")                   12g
80 Sets
$  325.00
$  26,000.00

Origin : China



5
Automatic Transfer                                   5g
125 Sets
$  20.00
$  2,500.00

Origin : China                          7g
125 Sets
$  20.00
$  2,500.00

12g
200 Sets
$  20.00
$  4,000.00
6
Twist Yarn Travers Winder
14 Sets
$  520.00
$  7,280.00

08 Spindles




Origin : China



7
Dial Linking Machine




Without Stand, Chair & Motor             14g
150 Sets
$  145.00
$  21,750.00

16g
50 Sets
$  150.00
$  7,500.00

5g
45 Sets
$  140.00
$  6,300.00

6g
15 Sets
$  140.00
$  2,100.00

8g
80 Sets
$  140.00
$  11,200.00





8
Automatic Washer Machine




Origin : China, Capacity: 70kg
3 Sets
$  5,400.00
$  16,200.00





9
Hydro Extractor




Origin : China, Capacity: 70kg
3 Sets
$  3,800.00
$  11,400.00





10
Industrial Auto Dryer




Origin : China, Capacity: 70kg
5 Sets
$  5,500.00
$  27,500.00





11
Inspection Equipment                       38"
4 Sets
$  390.00
$  1,560.00

                                                            40"
4 Sets
$  405.00
$  1,620.00

Origin : Taiwan








12
Industrial Steam Iron
35 Sets
$  115.00
$  4,025.00





13
Automatic Strap Knitting Machine 7g
3 Sets
$  800.00
$  2,400.00

With Double Heads (Needle Bed 18") 12g
4 Sets
$  800.00
$  3,200.00

Origin : China








14
M-7-Fur-Waste Brushing-Off Machine
2 Sets
$  3,000.00
$  6,000.00

Origin : China








15
Standard Accessories
1 Lot

$  10,000.00
Total
$ 421,585.00

Sewing machine required for the sweater project
BRAND: JUKI/BROTHER
Sl
Description
Quantity
Unit Price
Amount
1
Plain Machine
14 Sets
$ 400.00
$ 5,600.00
2
Overlock Machine
10 Sets
$ 900.00
$ 9,000.00
3
Button Hole Machine
4 Sets
$ 4,500.00
$ 18,000.00
4
Button Stich Machine
4 Sets
$ 4,250.00
$ 17,000.00
5
Bartek Machine
4 Sets
$ 3,100.00
$ 12,400.00
6
Flat Lock Machine
2 Sets
$ 1,350.00
$ 2,700.00
Total
$ 64,700.00

Other machinery
Description
Quantity
Unit (Appx)
Amount
Boiler Machine Required: Capacity-470kgs/H
2 Sets
$ 22,492.00
$ 44,984.00
Generator Required: Capacity-350kva
Brand: F.J. Wilson
1 Sets
$ 22,492.00
$ 22,492.00
Metal Detector
1 Sets
$ 12,000.00
$ 12,000.00
Total
$ 79,476.00

Cost of local machinery required for this project

Sl
Particulars
Quantity
Unit Price
Amount
1
Label Cutting Machine
4 Sets
$ 35.71
$ 142.86
2
Drawstring Machine
2 Sets
$ 428.57
$ 857.14
Total
$ 1,000.00


Furniture | Equipment

Sl
Description
Quantity
Unit Price
Amount
1
Knitting Stand (For 36" & 42" Needle Bed)
400 Pcs
$ 31.43
$ 12,571.43
2
Knitting Side Table
800 Pcs
$ 10.00
$ 8,000.00
3
Knitting Measurement Table
12 Pcs
$ 57.14
$ 685.71
4
Knitting Inspection Table
6 Pcs
$ 142.86
$ 857.14
5
Knitting Weight Scale
4 Pcs
$ 142.86
$ 571.43
6
Linking Table With Motor
57 Pcs
$ 214.29
$ 12,214.29
7
Linking Inspection Table
4 Pcs
$ 142.86
$ 571.43
8
Linking Weight Scale
2 Pcs
$ 28.57
$ 57.14
9
Trimming Table
10 Pcs
$ 114.29
$ 1,142.86
10
Long Bench
20 Pcs
$ 28.57
$ 571.43
11
Mending Table
10 Pcs
$ 114.29
$ 1,142.86
12
Long Bench
20 Pcs
$ 28.57
$ 571.43
13
Table For Light Check
6 Pcs
$ 57.14
$ 342.86
14
Chair
6 Pcs
$ 14.29
$ 85.71
15
Iron Table
13 Pcs
$ 121.43
$ 1,578.57
16
Iron Side Table
35 Pcs
$ 14.29
$ 500.00
17
Iron Inspection Table
4 Pcs
$ 114.29
$ 457.14
18
P.Q.C. Table
9 Pcs
$ 114.29
$ 1,028.57
19
Long Bench
18 Pcs
$ 28.57
$ 514.29
20
Final Check Table
6 Pcs
$ 114.29
$ 685.71
21
Long Bench
12 Pcs
$ 28.57
$ 342.86
22
Packing Section Table
4 Pcs
$ 114.29
$ 457.14
23
Long Bench
8 Pcs
$ 28.57
$ 228.57
24
Incharge And Supervisor Table
60 Pcs
$ 71.43
$ 4,285.71
25
In-charge And Supervisor Chair
60 Pcs
$ 8.57
$ 514.29
26
Supervisor Cabinet
60 Pcs
$ 42.86
$ 2,571.43

Total


$ 52,550.00

Other expenses related to the different type of supporting materials for sweater production

Description
Amount
Winding Section:

Calculator
$ 14.29
Wooden Cones
$ 314.29
Knitting Section:

Yarn Distribution Table (4sets) And Chair (4 Sets)
$ 228.57
Linking Section:

Distribution Table And Chair
$ 228.57
Basket
$ 1,000.00
Triming Section:

Chair (1set) And Table (1set)
$ 42.86
Basket
$ 114.29
Mending Section

Chair (1set) And Table (1set)
$ 42.86
Basket
$ 114.29
Washing Section
$ 1,500.00
Packing Section

Basket
$ 114.29
PQC & Final Check Section

Basket
$ 114.29
Store Section

Rack For Keeping Parts
$ 857.14
Almirah (2sets)
$ 142.86
File Cabinet (2 Sets)
$ 71.43
Table (1set) & Chair (1set)
$ 42.86
Maintenance Section

Tools
$ 285.71
Office

Fax Machine (1 Set)
$ 571.43
Photocopy Machine (1 Set)
$ 1,142.86
Type Writer (1set)
$ 142.86
Computer (2 Sets)
$ 1,142.86
Telephone (2sets)
$ 428.57
Almirah (2sets)
$ 114.29
File Cabinet (4 Sets)
$ 114.29
Total
$ 8,885.71


Required Manpower

Winding Section
Sl
Position
No
Salary Condition
Basic & Salary
Total
01
Yarn Controller
01
Fixed Pay
$ 171.43
$ 171.43
02
Distributor
04
Fixed Pay
$ 71.43
$ 285.71
03
Operator
14
Fixed Pay/Produc
$ 42.86
$ 600.00
04
Helper
06
Fixed Pay
$ 40.00
$ 240.00
Total
14


$ 1,297.14

Knitting Section
Sl
Position
No
Salary Condition
Basic & Salary
Total
01
In Charge
01
Fixed Pay
$ 214.29
$ 214.29
02
Supervisor
26
Fixed Pay
$ 92.86
$ 2,414.29
03
Distributor
08
Fixed Pay
$ 85.71
$ 685.71
04
Asstt Distributor
02
Fixed Pay
$ 64.29
$ 128.57
05
Inspection
10
Production
$ 57.14
$ 571.43
06
Operator
800
Production
$ 40.00
$ 32,000.00

Total
26


$ 36,014.29

Linking Section
Sl
Position
No
Salary Condition
Basic & Salary
Total
01
Linking In Charge
01
Fixed Pay
$ 214.29
$ 214.29
02
Distributor
04
Fixed Pay
$ 85.71
$ 342.86
03
Technician
01
Fixed Pay
$ 128.57
$ 128.57
04
Inspection
06
Fixed Pay
$ 71.43
$ 428.57
05
Operator
340
Production
$ 40.00
$ 13,600.00
06
Supervisor
14
Fixed Pay
$ 92.86
$ 1,300.00
07
Helper
06
Fixed Pay
$ 40.00
$ 240.00
Total



$ 16,254.29

Trimming Section
Sl
Position
No
Salary Condition
Basic & Salary
Total
01
Operator
65
Production
$ 57.14
$ 3,714.29
02
Supervisor
02
Fixed Pay
$ 92.86
$ 185.71
03
Light Check Operator
08
Production
$ 50.00
$ 400.00

Total



$ 4,300.00

Zipper Tuck Section
Sl
Position
No
Salary Condition
Basic & Salary
Total
01
Supervisor
01
Production
$ 85.71
$ 85.71
02
Operator
15
Fixed Pay
$ 57.14
$ 857.14

Total



$ 942.86

Sample Section
Sl
Position
No
Salary Condition
Basic & Salary
Total
01
Designer
01
Fixed Pay
$ 328.57
$ 328.57
02
Sample Man (Knitting)
06
Fixed Pay
$ 100.00
$ 600.00
03
Sample Man (Linking)
02
Fixed Pay
$ 85.71
$ 171.43

Total
09


$ 1,100.00

Mending Section
Sl
Position
No
Salary Condition
Basic & Salary
Total
01
Supervisor
02
Fixed Pay
$ 85.71
$ 171.43
02
Operator
40
Production
$ 57.14
$ 2,285.71

Total
40


$ 2,457.14

Washing Section (Including Dryer, Boiler & Hydro Extractor)
Sl
Position
No
Salary Condition
Basic & Salary
Total
01
Supervisor
01
Fixed Pay
$ 85.71
$ 85.71
02
Machine Operator
10
Fixed Pay
$ 57.14
$ 571.43
03
Helper
10
Fixed Pay
$ 42.86
$ 428.57

Total
21


$ 1,085.71

Iron Section
Sl
Position
No
Salary Condition
Basic & Salary
Total
01
Supervisor
02
Fixed Pay
$ 114.29
$ 228.57
02
Inspection
06
Fixed Pay
$ 71.43
$ 428.57
03
Sample Man
02
Fixed Pay
$ 71.43
$ 142.86
04
Operator
35
Production
$ 64.29
$ 2,250.00

Total
45

$ 0.00
$ 3,050.00

Sewing Section Section
Sl
Position
No
Salary Condition
Basic & Salary
Total
01
Sewing Machine Operator
14
Fixed Pay
$ 57.14
$ 800.00
02
Over Lock Operator
10
Fixed Pay
$ 78.57
$ 785.71
03
Flat Lock Operator
02
Fixed Pay
$ 57.14
$ 114.29
04
Buttonhole Operator
04
Fixed Pay
$ 57.14
$ 228.57
05
Button Stitch Operator
04
Production
$ 57.14
$ 228.57
06
Bartack Machine
04
Fixed Pay
$ 57.14
$ 228.57
07
Technician
01
Fixed Pay
$ 171.43
$ 171.43
08
Helper
05
Fixed Pay
$ 40.00
$ 200.00

Total
44

$ 0.00
$ 2,757.14

Production Quality Control Final Check Section
Sl
Position
No
Salary Condition
Basic & Salary
Total
01
In Charge
01
Fixed Pay
$ 200.00
$ 200.00
02
Supervisor
02
Fixed Pay
$ 100.00
$ 200.00
03
Operator
40
Fixed Pay
$ 57.14
$ 2,285.71

Total
45

$ 0.00
$ 2,685.71

Quality Control Section
Sl
Position
No
Salary Condition
Basic & Salary
Total
01
Quality Controller
08
Fixed Pay
$ 100.00
$ 800.00

Total
08


$ 800.00

Packing Section
Sl
Position
No
Salary Condition
Basic & Salary
Total
01
Supervisor
01
Fixed Pay
$ 114.29
$ 114.29
02
Packing Man
20
Production
$ 57.14
$ 1,142.86

Total
21


$ 1,257.14

Store Section
Sl
Position
No
Salary Condition
Basic & Salary
Total
01
Store In Charge
01
Fixed Pay
$ 171.43
$ 171.43
02
Asstt. Store In Charge
02
Fixed Pay
$ 57.14
$ 114.29
03
Loader
10
Fixed Pay
$ 54.29
$ 542.86

Total
13


$ 828.57

Security Section
Sl
Position
No
Salary Condition
Basic & Salary
Total
01
Security (Male)
08
Fixed Pay
$ 57.14
$ 457.14
02
Security (Female)
05
Fixed Pay
$ 50.00
$ 250.00

Total
13


$ 707.14

Office
Sl
Position
No
Salary Condition
Basic & Salary
Total
01
Production Manager
01
Fixed Pay
$ 857.14
$ 857.14
02
Asst. Prdn Manager
02
Fixed Pay
$ 428.57
$ 857.14
03
Accounts Manager
01
Fixed Pay
$ 571.43
$ 571.43
04
Accountant
04
Fixed Pay
$ 142.86
$ 571.43
05
Commercial Manager
01
Fixed Pay
$ 571.43
$ 571.43
06
Commercial Officer
01
Fixed Pay
$ 285.71
$ 285.71
07
Commercial Assitant
01
Fixed Pay
$ 71.43
$ 71.43
08
Quality Manager
01
Fixed Pay
$ 571.43
$ 571.43
09
Merchandising Manager
01
Fixed Pay
$ 1,000.00
$ 1,000.00
10
Merchandiser
01
Fixed Pay
$ 500.00
$ 500.00
11
Admin Officer
01
Fixed Pay
$ 214.29
$ 214.29
12
Office Asstt
02
Fixed Pay
$ 85.71
$ 171.43
13
Time Keeper
06
Fixed Pay
$ 71.43
$ 428.57
14
Peon
02
Fixed Pay
$ 42.86
$ 85.71
15
Cleaner
08
Fixed Pay
$ 42.86
$ 342.86
16
Helper
05
Fixed Pay
$ 50.00
$ 250.00
17
Security In Charge
01
Fixed Pay
$ 92.86
$ 92.86
18
Purchase Asstt
01
Fixed Pay
$ 157.14
$ 157.14

Total
40


$ 7,600.00

Production Quality Control Final Check Section

Sl
Position
No
Salary Condition
Basic & Salary
Total
01
Doctor
01
Fixed Pay
$ 357.14
$ 357.14
02
Nurse
02
Fixed Pay
$ 85.71
$ 171.43

Total
3


$ 528.57

Working Capital Calculation

01
Winding Section
For 25 Persons
$ 1,297.14
02
Knitting Section
For 847 Persons
$ 36,014.29
03
Linking Section
For  372 Persons
$ 16,254.29
04
Trimming Section
For 75 Persons
$ 4,300.00
05
Zipper Tuck Section
For 16 Persons
$ 942.86
06
Sample Section
For 09 Persons
$ 1,100.00
07
Mending Section
For 42 Persons
$ 2,457.14
08
Washing Section
For 21 Persons
$ 1,085.71
09
Iron Section
For 45 Persons
$ 3,050.00
10
Sewing Section
For 44 Persons
$ 2,757.14
11
PQC & Final Check
For 43 Persons
$ 2,685.71
12
Qc Section
For 08 Persons
$ 800.00
13
Packing Section
For 21 Persons
$ 1,257.14
14
Store Section
For 13 Persons
$ 828.57
15
Security Section
For 13 Persons
$ 707.14
16
Office Expenses
For 40 Persons
$ 5,900.00
17
Medical Deptt
For 03 Persons
$ 328.57
Total
$ 81,765.71
Gas & Electricity Bills
$ 3,571.43
Misc. Expenses
$ 1,071.43
Stationery
$ 714.29
Total
$ 87,122.86

Total Working Capital For 3 Months 87,122.86 X 3 =
$ 261,368.57

Total Cost Calculation

01
Machine For Knitting & Others
$  421,585.00
02
Machine For Sewing & Others
$  64,700.00
03
Boiler (470 Kg X 2)
$  44,984.00
04
Metal Detector (1 Set)
$  12,000.00
05
Local Machine
$  1,000.00
06
Local Furniture/Equipments
$  52,550.00
07
Other Expenses For Supporting Equipments
$  8,885.71

Sub Total
$  605,704.71

01
Electrical Sub Station
$  40,000.00 (Appx)
02
Electric Connection & Materials
$  42,500.00 (Appx)
04
Generator 350kv
$  22,492.00 (Appx)
05
Gas Connection
$  7,200.00 (Appx)
06
Water Line & Deep Tube Well
$  20,000.00 (Appx)
07
Fire Equipment
$  4,200.00 (Appx)
08
Documentation
$  11,000.00 (Appx)

Sub Total
$  147,392.00 (Appx)


09
Working Capital For 3 Months
$  261,368.57 (Appx)


Grand Total
$  1,014,465.29

Productivity and Profit

Normal working hour
10 Hrs/Day
Working Days
22 Days(Avg)

 X 12 Months =264 Days/Year

Capacity of Production
3G Knitting Machine       150 x 8 pcs x 264 Days
3,16,800 Pcs
5G/7G Knitting Machine  250 x 7 pcs x 264 Days
4,62,000 Pcs
12G Knitting Machine      400 x 5 Pcs x 264 Days
5,28,000 Pcs
Total
13,06,800 Pcs/1,08,900 Dz

Expected Turn over (FOB Price)
3G -- 3,16,800 (Pcs) = 26,400 Dz @ $  51.00
$  13,46,400.00
5G/7G -- 4,62,000 (Pcs) = 38,500 Dz @ $  54.00
$  20,79,000.00
12G -- 5,28,000 (Pcs) = 44,000 Dz @ $  48.00
$  21,12,000.00
Total
$  55,37,400.00

Expected profitability @ 4% of Turnover
$  2,21,496.00

Note: Though normal profitability in sweater industry in Bangladesh is around 6% of turnover, here it is calculated it in a conservative way.

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