Bangladeshi Labor and the Attraction of the Textile Industry




“Bangladeshi Labor and the Attraction of the Textile Industry”
Authors: Eduardo Gonzalez 
&
Elizabeth Lugo
Florida International University,
USA



Introduction:
The world economy is constantly changing and shifting from location to location, in search of the next most efficient location that can produce goods. This has been true since the “Silver Century” when Europeans traveled the world in search for goods that would bring them profit in return for things that they had in abundance (Brook). The race to the bottom is characterized by this motive. It is a way of attaining efficiency and in certain places, avoiding the markets (Rivoli). However this race has become natural in the quest for the success of businesses and the development of countries. The race to the bottom searches for cheap labor, cheap investments, and flexible regulations. When there are no more of these things in a given area, the race moves on in search of a place that will grant producers flexibility and cost efficiency. All of this is for not if a sizeable workforce is not found. We pose the question “What aspects of Bangladeshi labor attract the textile industry?” We will analyze labor in Bangladesh and why it is so attractive to foreign companies. It is important to understand that labor is not only the people, but the living and financial conditions of people as well as the social dependencies that these people have. Labor provides the gears for which production can become efficient. The wages of workers, the facilities of workers, and the regulations of workers can become obstacles to producers that can make or break their investments. It is necessary to have a workforce that can be content with receiving jobs from foreign producers to be able to operate with cost efficient investments. Bangladesh satisfies the aforementioned criteria. It is a country that is rising in the world arena and is considered one of the next places for the race to the bottom.

Background to Bangladeshi Labor:
Bangladesh has a population of more than 127.5 million people (globalfootprints.org). It is one of the most densely populated countries in the world. Most people live below the living standard, forcing the majority of people to seek jobs that will provide them with more profit. The Bangladeshis that live in rural areas move to the cities where there are supposed to be jobs and better living conditions. However, there are fewer jobs and homes than there are people moving to the cities, thus producing a string of shantytowns where people live in terrible conditions (globalfootprints.org). These conditions have led people to welcome the coming of textile factories and the development of the industry in Bangladesh. Textile manufacturers are always looking for the next location that will give them an edge in efficiency and cost. They need to find places that will provide them with an efficient labor force and that will render their investments more valuable than anywhere else. Bangladesh seems to be the place where the textile industry has shifted to in response to the multitude of Bangladeshis that need consistent and substantial wages.
Labor in Garment Industry
The labor force in Bangladesh is primarily comprised of women. The garment sector alone has a workforce that is 85 percent women. This has been the result of the type of work that women must tend to in rural areas. This work typically requires strength and long periods of time outdoors. Women are thus poorer and at a disadvantage when it comes to the work a man can typically accomplish in rural areas (nationsencyclopedia.com). Like the Chinese women in textile factories from PietraRivoli’s book, “The Travels of a T-Shirt in the Global Economy”, Bangladeshi women experience the same issues in rural areas. Their aspirations and living conditions force them to seek jobs that will get them away from the harsh work and at the same time provide them with an opportunity to escape the poverty they experience in rural areas.

The economic and social history of Bangladesh can be traced to 1971 when the country gained its independence. Since then it has increased its real per capita by 130 percent and has been able to cut poverty levels by 50 percent (ruralpovertyportal.org). To understand the drastic transformations the country has undergone, one must perceive it as a mostly rural country with agriculture being its original and primary form of revenue. Urbanization has changed this and emphasized on industrial development instead of agricultural development (ruralpovertyportal.org). Rural Bangladeshis have been left with little land and have been forced to rethink their lifestyles. The process of urbanization and the rise of factories have required more land, specifically land that has belonged to rural Bangladeshis. The country still employs 44 percent of its labor in the agricultural sector (ruralpovertyportal.org). Aside from this statistic, Bangladesh can be considered the current country in the race to the bottom as textile manufacturers seek workers that will work for lower wages.

Labor has specifically attracted the textile industry to Bangladesh because of the huge workforce and the relatively low wages that Bangladeshis are willing to accept. The current average wage is five thousand takas per month (Kiron). Eighty takas are equivalent to one dollar. This makes the monthly wage of a worker to be around sixty-two dollars. There are also several other reasons why companies have chosen to target Bangladesh for investment. In regards to labor, the country has a large segment of the population that is young and takes part in the labor force. 57 percent of the population is under 25 years old. They are also highly literate, having a 72 percent literacy rate (leopardasia.com). This part of the population can provide more work efficiency than a labor force that is older. Companies address efficiency concerns by investing in countries that will obviously provide them with more output at a lower cost. 78 percent of the country’ export earnings come from the textile sector. This sector accounts for 5 percent of the country’s total national income (Malhorta). This gradual ascendency has turned Bangladesh into the prime candidate for the next country in the race to the bottom. Cheap labor that is educated and plentiful makes for a very lucrative opportunity for textile companies. Despite all of these attractive characteristics of the country’s labor, unemployment persists and people continue to live in below standard conditions.

Considering the youthful labor force is significant, when comparing Bangladesh’s current economic state to its condition in the 1980s. During the 1960s and the 1970s there was a vast growth in people being born and this has predominantly led to the current wave of young workers in the 1990s and the 2000s. The Bangladeshi labor force has gone from 30.9 million in 1985-1986 to 56 million in 1995-1996 (nationsencyclopedia.com). This increase is a product of the rise in population and the search for a better lifestyle in cities. A significant portion of the labor force is employed in rural areas. Work in rural areas is very harsh and drives people to finding jobs that will be relatively more comfortable and that will pay better (nationaencyclopedia.com).

Our research led us to a textile engineering student in Bangladesh named Mazharul Islam Kiron. He operates his own blogging site specifically based on textiles. He relayed to us the current predicament of the labor force in Bangladesh. Kiron said that most people live below the living standard in Bangladesh. Unemployment is a common problem in this country and the garment sector seems to alleviate this issue. Kiron said that it is the largest field in terms of providing employment to people. He tells that around 50 lakh people are involved in the garment industry alone. This is equivalent to 5 million people. The sheer amount of people working on textiles alone is evidence to what a growing sector textiles has become for Bangladesh. The country has the potential to outmaneuver many other countries home to textile factories because of the evident devotion to textiles and the continued employment growth in the sector. The textile industry has benefited from the conditions in Bangladesh because of the need for employment, the migration of rural Bangladeshis to cities, and because of the low wages being paid to the workers when compared to the developed countries where these firms come from.

The MFA and Bangladesh:
Despite these favorable conditions for the development of the textile industry, Bangladesh has only recently been targeted by companies to produce textiles. January 1, 2005 marked the end of the MFA, or Multi Fiber Agreement, which had led the world of textiles and garments since 1974. The MFA imposed quotas on the amount developing countries could export to developed countries (Saxena). The quotas posed a problem for developing countries. However the EU did not impose such restrictions on these countries, one of which was Bangladesh. This gave way to a massive expansion of the RMG sector, the Ready-Made Garments sector in the country. Although Bangladesh was expected to suffer in comparison to other competitors such as China, orders for textile goods kept coming after the MFA expired and reached an expert overturn of about $10.7 U.S. dollars in the year 2007 (Saxena).

Productivity and competitiveness have been the major issues that Bangladesh has faced since the fall of the MFA. International trade strategies, international garment buyers, and international NGOs combined with coalition building among stakeholders in the sector has resulted in significant and favorable changes at both the government and factory levels. This has allowed Bangladesh to remain competitive and has resulted in an unprecedented cooperative movement. Although Bangladesh is predicted to do well in the RMG sector, in order to expand it needs to make investments in human capital and technology, rather than just reduce costs. These investments will stimulate the creation of positive working environments and will provide the needed stimulation for the industry to innovate and prosper.

In an interview for the Asia Foundation’s Economic Reform and Development Program, BGMEA (Bangladesh Knitwear Manufacturers and Exporters Association) president Falzul Haq stated, “Bangladesh is doing well after the end of the MFA, but we are not satisfied. We have the potential to grow more… [the question is] do we want to do 25 million dollars of business, or stay at 10.5 million?” The year 2008 proved to be important for the garment industry. Vietnam entered the WTO in 2008, which made the country one of the largest competitors for Bangladesh and the recession in the U.S. and EU markets gave way to a decline in imports from the Bangladeshi market (Saxena).

In a study conducted in Dhaka in January and November of 2008 by the Asia Foundation for Economic Reform and Development, various groups of people were interviewed and asked their notion of competitiveness and what they thought were the key factors for success at the factory level and state level. These four groups were international buyers, government officials, factory owners and middle managers. Some factory workers were also interviewed. Although these groups had different opinions, they all ultimately agreed that productivity was the most important factor in ensuring competitiveness for the Bangladeshi market. These groups also agreed that productivity was the area that needed the most improvement (Saxena). When asked, factory workers stated that the quality of products, wages, good working conditions, healthcare, and training were factors that affected a factory’s competitiveness (Saxena).

Perception of what constitutes good working conditions has changed over time amongst factory workers. In previous years, workers wanted their basic needs such as increased wages, healthcare and safety to be met, but in more recent years, demands for respect and the yearning to be heard have risen among the workers. This has led many in the garment sector to emphasize on establishing a positive work and factory culture, motivating workers, and communicating with them (Saxena). In 2008 workers still linked productivity and increased wages. A worker stated, “If wages are increased, the quality of work will improve and more buyers will come” (Saxena).

International retailers agreed that it is cost, along with productivity, that makes a factory competitive. Reliability and pre-production assistance are also factors that were identified as pre-conditions for an international buyer to trust a factory. National labor laws and international labor standards were also mentioned as conditions for export to the U.S. and EU. Compliance to these is now considered necessary, but not sufficient, for a factory to maintain its competitiveness. Buyers mentioned an appreciation for Bangladesh’s quality amongst its entrepreneurs and its work force (Saxena).

Government assistance has become necessary in order for competitiveness in the Bangladeshi textile sector to thrive. Factory managers and international buyers agree with such aid. Both groups expressed a need for more infrastructure, trade facilitation and cost of production (Saxena). Workforce and productivity are amongst the most important factors that make Bangladesh a competitive country in the garment sector, but the poor infrastructure and working conditions are amongst its weaknesses.

Bangladesh has proved its ability to be a low cost producer of quality goods after the phasing out of the MFA. If investments in training, labor conditions, and infrastructure are made, along with producing quality items, Bangladesh will remain among the top sources for international buyers and secure its position as a top competitor in the textile industry.

Labor Laws and Conditions:
The flexibility of labor in Bangladesh is also protected by laws. Even though companies have taken advantage of the lax restrictions in Bangladesh, there have recently been laws implemented that protect workers. The recent, Labor Act 2006, and other similar policies have been established to provide workers with appropriate holidays, work hours, safety, minimum wages, and justification for dismissals. This gives workers a guarantee that their jobs are safe and that they will work in a healthy environment (legalsteps.com.bd). In Bangladesh the weekly holidays are Friday and Saturday. Workers typically work 8 and a half hour a day and can stop for a meal and prayer. The total work hours per week sum up to be 48 hours (boi.gov.bd). This framework helps create a standard from which workers can compare with their own jobs. It can help them make demands for fair treatment and avoid being exploited. Kiron made a point that has relevance to this issue. He recalled that there had been a series of strikes on behalf of the work unions in response to poor wages and facilities. This was a small occurrence and nothing out of the ordinary, but it demonstrates that workers have a voice in determining how they work and resolving issues in the workplace. Worker unions in Bangladesh have a lot of say in working conditions and privileges. They are usually affiliated with a political party which gives them some sort of leverage in the government (nationsencyclopedia.com). As a result of this collective action, workers can ask for better wages r better facilities as was the matter of the aforementioned demands.

However, workers unions have not been as effective in the private sector. These unions are banned from Export Processing Zones, or EPZs, and these areas are even exempt from the labor laws. In 2004 worker association was permitted, but in 2007 this was revoked by a state of emergency and restrictions were implemented on unionization (solidaritycenter.org). EPZs are even exempt from having to abide by certain labor laws (nationsencyclopedia.com). Companies involved in the textile industry could take advantage of the labor force without having to abide by certain labor laws that would otherwise limit their ability to control cost efficiency. Having factories in Bangladesh allows them to be flexible with wages and prerequisites.

These exemptions seem to be made to attract foreign investment. Companies will want to invest in a location that can give them flexibility and a significant workforce. This particular aspect of labor combined with the current situation of the workforce in Bangladesh has generated the ideal scenario for Bangladesh to become the next large competitor for foreign investment in the world. A reliable and conscious workforce is crucial to generate a positive output. Labor in Bangladesh has several aspects that make it more attractive than labor in many other locations. Bangladesh has a large amount of workers that are educated and these workers are in need of jobs. The currency is valued much lower than the dollar making it the ideal place for cost efficiency and competitiveness. The government even provides companies the ability to waive certain labor laws in order to maximize production in EPZs and attracting even more foreign investment. Labor in Bangladesh seems to have all of the ideal characteristics for foreign investment and the continued growth of the textile industry. Bangladesh produces quality goods that cost relatively less than in other locations and has a labor force that acknowledges this type of work. This makes the country the perfect candidate in the current race to the bottom.

Works Cited:
  1. Board of Investment Bangladesh. "Creating a Workforce." n.d. boi.gov.bd. Web. 2 December 2012.
  2. Brook, Tomothy. Vermeer's Hat. New York: Bloomsbury Press, 2009. Print.
  3. Global Footprints. Bangladesh. n.d. Web. 2 Demcember 2012.
  4. Mazharul Islam Kiron. Bangladeshi Labor Information Eduardo Gonzalez. 15 November 2012. Web.z
  5. Legal Steps. "Labour or Employment Law." n.d. legalsteps.com.bd. Web. 2 December 2012.
  6. Leopard Asia. "Why Invest in Bangladesh." n.d. leopardasia.com. Web. 2 December 2012.
  7. Malhorta, T.C. "Bangladesh: A Growing Textile Economy." n.d. textileworldasia.com. Web. 2 December 2012.
  8. Md. Amanur Rahman, David T. Parkes. "Bangladeshi Textile Industry Profitable Despite Recession." 19 March 2009. fibre2fashion.com. Web. 2 December 2012.
  9. Nations Encyclopedia. "Bangladesh- Working Conditions." n.d. nationsencyclopedia.com. Web. 2 December 2012.
  10. Rivoli, Pietra. The Travels of a T-Shirt in the Global Economy. Hoboken: John Wiley & Sons, Inc., 2009. Print.
  11. Rural Poverty Portal. "Rural poverty in Bangladesh." n.d. ruralpovertyportal.org. Web. 2 December 2012.
  12. Saxena, Dr. Sanchita Banerjee. "Competitiveness in the Garment and Textiles Industry: Creating a supportive environment A Case Study of Bangladesh." July 2010. asiafoundation.org. Web. 2 December 2012.
  13. Solidarity Center. "Bangladesh." n.d. solidaritycenter.org. Web. 2 December 2012. 
 

Applications of Smart and Interactive Textiles


SMART AND INTERACTIVE TEXTILES

Author: Saddamhusen Jamadar
D.K.T.E’S TEXTILE & ENGINEERING INSTITUTE, 
ICHALKARANJI, INDIA
Email: saddamjamadar75@gmail.com





ABSTRACT
Smart and interactive textiles are fibrous structures that are capable of sensing, actuating, generating/storing power and/or communicating. Research and development towards wearable textile-based personal systems allowing e.g. health monitoring, protection & safety, and healthy lifestyle gained strong interest during the last 10 years.

Smart fabrics and interactive textile wearable systems regroup activities along two different and complementary approaches i.e. "application pull" and "technology push". This includes personal health management through integration, validation, and use of smart clothing and other networked mobile devices as well as projects targeting the full integration of sensors/actuators, energy sources, processing and communication within the clothes to enable personal applications such as protection/safety, emergency and healthcare. so here in case of smart textiles we are using the conductive fibers such as metal yarn. This paper includes the origin and introduction of smart textile and integrated wearable electronics for sport wear, industrial purpose, automotive & entertainment applications, healthcare & safety. military, public sectors, and new developments in smart textiles.

The paper wishes to focus on smart and interactive textiles, therefore the whole paper is dedicated to this. Definitions, working conditions, purpose and applications in various fields of interactive textile are included here. As well as the future of smart and interactive textile also given in brief.

The paper wishes to give a good overview of the smart and interactive textile. And also gives idea about future textile with human.

INTRODUCTION
The original function of textiles was to shield man from cold and rain. Later on in history aesthetic aspects also came to play a role in clothing. Much more recently a new generation of textiles has arisen; smart and interactive textiles. Interactive textiles are a relatively new discipline in the textile sector. They are active materials that have sensing and actuation properties. Their potential is enormous. one could think of smart clothing that makes us feel comfortable at all times, during any activity and in any environmental conditions, a suit that protects and monitors, that warns in case of danger and even helps to treat diseases and injuries. Such clothing could be used from the moment we are born till the end of our life. Some of the more important efforts include applications that Aid in patient health monitoring through sensor embedded garments that track and record biometric data, Helps to improve athletic performance both by analyzing sensor data and adapting to changing conditions. So as to improve performance over the time .Provides environmental sensing and communication technologies for military defense and other security personals .Present new structural and decorative solutions for fashion design. Some them were described further in this paper.
Interactive Textile
The smart textile can sense and react to environmental conditions or stimuli from mechanical, thermal, chemical, electrical, magnetic or other sources. Three components must be present in smart textiles. i.e. sensors, actuators and controlling units. The sensor provides nerve system to detect signals some of materials acts as only sensors. And some acts as both the sensors and actuators. Smart textiles are combination of textile and electronics. Modified textile material and miniaturized electronic devices create smart cloths. These cloths are like ordinary cloth providing special function in various situations according to the design and application.

SMART MATERIAL & ITS CLASSIFICATION

“Smart material" is a generic term for a material that in some way reacts to its environment. Smart materials can be classified in many different ways, for example depending on their transforming function: property change capability, energy change capability, discrete size/location or reversibility. Smart materials can also be classified depending on their behavior and function as passive smart, active smart or very smart. Another way of classifying them is to look at the role they could have in a smart structure, as sensors or actuators. According to the manner of reaction, they can be divided into passive smart, active smart and very smart materials:
  1. Passive smart materials can only sense the environmental conditions or stimuli; they are sensors
  2. Active smart materials will sense and react to the condition or stimuli, besides the sensor function, they also have actuation characteristics.
  3. Very smart materials can sense, react and adapt themselves accordingly;
  4. An even higher level of intelligence can be achieved from those intelligent materials and structures capable of responding or activated to perform a function in a manual or pre-programmed manner.
Concepts for 5 interactive textile samples have been developed. The concepts are based on the following sensors: pressure sensors, sound sensors, strain sensors and light sensors; and actuator: shape memory alloys, light emitting diodes, electroluminescent materials, photovoltaic cells, optical fibres, thermo chromatic and photo chromatic inks. It should be mentioned that some materials are both sensors and actuators, such as thermo and photo chromatic inks. More concepts including other sensors and actuators could be developed to be included in the future.

MATERIALS
The materials of our surroundings are being “intellectualized”. Whereas, in the past, we needed several components to satisfy a certain function, technology today has allowed us to satisfy the same function with fewer components. “The new generation of objects, rather than being solidly located in space, tend to flow through time.” .These materials can interact, communicate and sense. Miniaturization not only means the production of smaller components, but the elimination of components. Mechanisms, that previously had to be manufactured by different materials and as separate objects, can now be made of one single material. Examples of this reduction of components and matter are; a complex sensor system replaced by a piezoelectric film and the mechanical keyboard replaced by the membrane.

Here we are using conductive metallic yarns like silver, stainless steel, carbon fiber textile yarns with electrical properties .yarns containing conductive fibers like stainless steel mix with natural synthetic fibers. Polymeric or carbon coated threads Conductive yarn, conductive rubber, and conductive ink have been developed into sensors or used as an interconnection substrate. Conductive yarns and fibers are made by mixing pure metallic or natural fibers with conductive materials. Pure metallic yarns can be made of composite stainless steel or fine continuous conductive metal-alloy Combination of fibers with conductive materials can be completed by the following methods:
  1. Fibers filled with conductive material (e.g., carbon or metallic particles);
  2. Fibers coated with conductive polymers or metal; and
  3. Fibers spun with thin metallic or plastic conductive threads.
Metallic silk, organza, stainless steel filament, metal clad aramid fiber, conductive polymer fiber, conductive polymer coating and special carbon fiber have been applied to the manufacture of fabric sensors.

Materials such as metallic, optical fibres and conductive polymers may be integrated into the textile structure, thus supplying electrical conductivity, sensing capabilities and data transmission. Organic polymers may provide a solution to overcome the stiffness of inorganic crystals such as silicon. These materials are light, elastic, resilient, mechanically flexible, inexpensive and easy to process.

Metal Fibers
Metal threads are made up of metal fibres which are very thin metal filaments(diameters ranging from 1 to 80 micron). The fibers are produced either through a bundle-drawing process or else shaved off the edge of thin metal sheeting. Metallic threads and yarns may be knitted or woven into a textile and used to form Interconnects between components. They may also be used as electrodes for monitoring electrical physiological activity such as electrocardiogram (ECG) signals. While metals provide good conductivity there are some drawbacks of integration into clothing. Metal threads tend to be heavier than most textile fibers and their brittle characteristics can damage spinning machinery over time and also they may be uncomfortable to wear due to abrasion.
Fig.1 Metal yarns
Conductive Inks
A layout can be screen-printed using conductive inks to add conductivity to specific areas of a garment. Carbon, copper, silver, nickel and gold may be added to conventional printing inks to make them conductive. Printed areas can be subsequently used as switches or pressure pads for the activation of circuits.
Fig.2 Conductive ink
Inherently Conductive Polymers
Inherently conductive polymers have both sensing and actuation properties. The electrical conductivity of these polymers is known to be caused by their conjugated double bond chain structure. Some commonly had known ICPs include polyacetylene, polypyrrole, polyaniline, and polythiophene. Polypyrrole (PPy) is most suitable as It has high mechanical strength with high elasticity, is relatively stable in air and electro active in both organic and aqueous solutions. Polypyrrole has be used in the development of organic piezo-resistive sensors by depositing thin layers of PPy, by anin situchemical polymerization process, onto fabrics with high elasticity such as nylon lycra® or high compressibility such as polyurethane foam. Conductivity changes results from external deformation of the material. The major advantage of this approach is that the sensors retain the natural texture of the material. How ever the problem with these devices is a variation in resistance over time, and a high response time.
Fig.3 Conjugate structure of ICP
Optical Fibers
Plastic optical fibres may be easily integrated into a textile. They have the advantage of not generating heat and are insensitive to EM radiation. Optical fibres may serve a number of functions in a smart garment - transmit data signals, transmit light for optical sensing, detect deformations in fabrics due to stress and strain and perform chemical sensing. Plastic optical fibres can be woven into a textile, however bending of the fibers is an issue during the manufacturing process and also with the end product as mechanical damage causes signal loss. Commercially available Luminex ®fabric is a textile with woven optical fibers capable of emitting its own light. While this has aesthetic appeal for the fashion industry it is also used in safety vests and potential to be used for data transmission.
Fig.4 Optical fibre
Coating with Nano-Particles
Coating a fabric with nano particles is being widely applied within the textile industry to improve the performance and functionality of textiles. Conventional methods of adding various properties to fabrics may not last after washing and wearing. How ever nanotechnology can add permanent effects and provide high durability fabrics. This is due to the large surface area-to-volume ratio and high surface energy of nano particles. Coating with Nano-particles can enhance the textiles with properties such asanti-bacterial, water-repellence, UV-protection and self-cleaning, while still maintaining breath-ability and tactile properties of the textile. Nano-Tex has a range of products using such coatings to resist spills, repel and release stains, and resiststatic. These textile enhancements become inherent to the fabric, improving the performance and durability of everyday apparel and interior furnishings.

Organic Semiconductors
Organic semiconductors, (polymers and oligomers), having the electrical properties of semiconductors and the mechanical properties of plastics, are good candidates for developing electronic and optoelectronic flexible components, e.g. transistors, LEDs, on the flexible textile substrate. Organic LEDs consist of multilayer structures where organic emitters are embedded between an evaporated metal electrode and a film of indium tin oxide coupled to a plastic or glass substrate. Philips have recently released light emitting fabric, Lumalive®, featuring flexible arrays of fully integrated colored LEDs. These light-emitting textiles can carry dynamic messages, graphics, or multicolored surfaces.

Shape Memory Materials
 
SMMs can deform from the current shape to a previously set shape, usually due to the action of heat. a strip of metal is heated with a lighter and finds its original shape. In garments the scale is smaller. When these SSMs are activated (at a certain activation temperature), the air gaps between close layers of clothing are increased. This is to give better insulation and protection against extremes of heat or cold. In clothing, the temperatures for the shape memory effect to be activated should be near body temperature.

SM Polymers are more flexible than the alloys. Thermoplastic polyurethane films have been made which can be put in between layers of clothing. When the temperature of the outer layer of clothing has fallen sufficiently, the film responds so that the air gap between the layers of clothing becomes broader. This out-of-plane deformation must be strong enough to resist the weight of the clothing and the movements of the wearer. If the outer layer of clothing becomes warmer, the deformation must be reversed. Some alloys are capable of a two-way activation, triggered by changeable weather and varying physical activity.
Chromic Materials
Chromic Materials are also called chameleon fibres, because they can change their color according to external conditions. These materials have mostly used in fashion, to create funny color changing designs. Because of this, some people fear that the chromic materials will be a short boom. But the accuracy and endurance of the materials are all the time being improved.

TYPES OF SENSORS:


1. BLOOD PRESSURE MEASURING SENSORS:

Pressure sensors include all sensors, transducers, and elements that produce an electrical signal proportional to pressure or changes in pressures. Pressure sensors are devices that read changes in pressure and relay this data to recorders or switches.

2. BODY TEMPERATURE MEASURING SENSORS
Thermistor are thermally sensitive devices whose electrical resistant varies with temperature. Unlike thermocouples, thermistors do not have standards associated with their resistance verses temperature.

There are two types of thermistors:
  1. Positive temperature coefficient (PTC)
  2. Negative temperature coefficient (NTC)
In PTC thermistor, electrical resistance increases as temperature increases. While in case of NTC thermistor, electrical resistance drops as temperature increases. Thermistors are more accurate than some other types of temperature sensors.

3. PULSE RATE MEASURING SENSORS

The easiest way to measure heart rate is using the heart rate sensors. Heart rate sensor monitors the light level transmitted through vascular tissues of the fingertip and the corresponding variations in light intensities that occurs as the blood volume change in the tissue. The ease of use makes it possible to measure everyone’s heart rate, even in larger classes. The heart rate sensors measuring heart rate between 0 and 200 bpm (beatsper minutes)

Unlike an electrocardiograph (ECG) which monitors the electrical signal of the heart, the heart rate by monitoring the changes in infrared transmittance through blood vessels, the amount of blood changes with time and the corresponding variation in light intensities changes. By this the heart rate can be determined.

NETWORKING AND COMMUNICATION
In this where data acquisition from many sensors is involved. Issues such as addressing of the individual sensors, the layout of the data paths within the fabric. The placement of the processing units and the routine strategies all play a significant role in the design of the fabric. In terms of its power consumption.
INTERCONNECTION
This might be one of most difficult areas dealt with in the electronics industry and interconnection involves either connecting two wires or connecting an electronic component to a wire. The common method that is used for both these interconnections is soldering. Components can also be connected to the wires using insulation. Displacement connecters and spot welding on the other hand stitching interconnects two pieces of fabric. When two pieces of E-textiles have to be interconnected both these issues have to be considered simultaneously. Thus there is need to develop interconnection between electronic components and textile.

POWER SUPPLY
The power supply is the biggest problem. Power supply technologies typically batteries provide the electrical power for activating components in an electronic textile. In recent years, batteries have not only become smaller and more powerful water resistant and lower cost. One type is fabricated by screen printing silver oxide based paste on a substrate to yield battery only 120 microns thick, solar energy and energy created by the human body are also being studied as sources of electrical power for electronic components. Two of the most known approaches to develop new power supply technologies, are lithium polymer battery and micro fuel cells. Sunlight, body temperature and body motion are alternative energy sources on the body that can be transformed into electrical energy. Also in this case, one should differ between flexible and textile, because there are more efforts to mount flexible energy supplies onto textiles than inventing pure textile power supply.

Thin film solar cells can be made on flexible surface technology has also been adapted to fibre form. The efficiency of these alternative energy sources needs to be improved.

APPLICATIONS OF SMART AND INTERACTIVE TEXTILES IN VARIOUS FIELDS

1. HEALTH CARE
The development of wearable monitoring systems is already having an effect on healthcare in the form of “Telemedicine”. “The integration of high-technology into textiles, e.g. modern communication or monitoring systems or the development of new materials with new functions, has just started with timidity, but the branch already propagates an enormous boom for this sector Personalized Health care The concept of personalized healthcare empowers the individual with the management and assessment of their own healthcare needs. Wearable devices allow physiological signals to be continuously monitored during normal daily activities. This can overcome the problem of infrequent clinical visits that can only provide a brief window into the physiological status of the patient. Smart clothing serves an important role in remote monitoring of chronically ill patients or those under going rehabilitation. It also promotes the concept of preventative healthcare. Given the current world demographics there is a need to shift the focus of healthcare delivery from treatment to prevention and also to promote wellness monitoring rather than diagnosis of illness.

SFIT for personal health monitoring, "so called" intelligent biomedical clothing was initiated in the early.

It is one of the most important applications for SFIT wearable systems. The first promising results (prototypes) have been achieved by few research teams in Europe and USA, following the "application pull" approach. These prototypes incorporate mainly electrocardiogram and respiration monitoring (and accessorily other physiological and physical parameters depending on the targeted applications) by implementing strain fabric sensors and fabric electrodes. Representative examples are e.g.:
  • Wireless-enabled garment with embedded textile sensors for simultaneous acquisition and continuous Monitoring of ECG, respiration, EMG, and physical activity. The “smart cloth” embeds a strain fabric sensor based on piezo resistive yarns and fabric electrodes realized with metal based yarns.
  • Sensitized vest including fully woven textile sensors for ECG and respiratory frequency detection and a Portable electronic board for motion assessment, signal pre-processing, and Bluetooth connection for data Transmission.
  • Wearable sensitized garment that measures human heart rhythm and respiration using a three lead ECG shirt. The conductive fiber grid and sensors are fully integrated (knitted) in the garment (Smart Shirt).

Fig.5 shirt for measuring rehabilitation
LIFE BELT:
Life belt is a trans-abdominal wearable device for long-term health monitoring that facilitates the parental monitoring procedures for both the mother and the fetus. Hospitals and obstetric clinics, on the other hand, might avoid the frequent visit of additional patients (most of them hypochondriacs), so the remote health monitoring provided by this.

“Life belt” will contribute to a significant reduction of the hospitals’ load. The hospitals’ efficiency in that way can be increased as well as the quality of the provided services. “life belt” is also a valuable decision support tool for the obstetrician, who is enabled to monitor patients remotely, evaluate automated preliminary diagnosis of their condition based on collected and analyzed vital signs, access patients’ medical data at any time and most importantly be alerted when potential pregnancy complications require physical examination of the patient. Furthermore, the obstetricians are able to use mobile units and portable devices to organize their work and increase their work efficiency and effectiveness. so this life belt is very useful in case of pregnant women .Pregnant women living in remote areas work during pregnancy and face certain health problems (e.g. high blood pressure, kinetic problems requiring immobilization, kidney or heart diseases, multiple pregnancy). Usually they feel uncomfortable with frequent visits for prenatal monitoring. The inaccessibility of the fetus, the sensitivity of fetal and maternal health status and susceptibility to psychological conditions pose significant difficulties in monitoring the progress of the pregnancy effectively. Furthermore, bulky or invasive equipment and long examinations in clinical settings affect both the mother and the fetus causing additional stress which influences their health. The use of a wearable platform able to monitor non-invasively fetal and maternal vital signs could improve significantly their living conditions.

LIFE JACKET:
Life jacket is a medical device worn by the patient that consequently reads their blood pressure or monitors the heart rate; the information is transferred to a computer and read by medical staff. A specialized camera in the form of headwear has been developed to be worn by paramedics. Visual information captured by the camera can be transferred directly to medical staff at the hospital enabling them to advise instantly on appropriate treatment.

Hypertension is another common disease found in the elderly population. Elevated BP increases the workload of the heart and scars the artery walls. Increases in either BP or BP variability (BPV) are partly responsible for various cardiovascular events. Nevertheless, most individuals with hypertension experience no symptoms, which often make them overlook their ailment. Thus, early detection of BP for health condition assessment by wearable devices before a severe event occurs is very important. Technologies advanced in
Fig.1 Life jacket
Wearable BP monitoring focuses on continuous and noninvasive measurement without using a cuff. Cuff-less BP can be measured from the radial pulse waveform by arterial tonometry by using this life jacket.

Table1. E-textile sensors in health monitoring
One consideration is that attaching sensors to the body can cause skin problems. “An alternate solution is textile-structured electrodes, which are ECG sensors embedded inside garments, such as fiber, yarn, and fabric structures. These textile-structure electrodes, possibly woven into clothes, are more comfortable and suitable for long-term monitoring. “It’s possible to acquire a host of signals: electrocardiogram, electromyogram, respiration signal, skin conductivity, index of movement. To this purpose, fabric piezo resistive sensors, fabric electrodes and textile connections are integrated and knitted in one step process given rise to comfortable sensing garments.”

Two EU-funded projects, WEALTHY and MyHeart, involve a wearable textile interface integrating sensors, electrodes and connections realised with conductive and piezoelectric yarns for monitoring vital signs. New products coming onto the market for similar applications include the Smartshirt by Sensatex™ and the Life Shirt® system by Vivometrics®, offering continuous ambulatory monitoring systems for the healthcare sector.

2. MILITARY/DEFENSE

In extreme environmental conditions and hazardous situations there is a need for real time information technology to increase the protection and survivability of the people working in those conditions. Improvements in performance and additional capabilities would be of immense assistance within professions such as the defense forces and emergency response services. The requirements for such situations are to monitor vital signs and ease injuries while also monitoring environment hazards such as toxic gases. Wireless communication to a central unit allows medics to conduct remote triage of casualties to help them respond more rapidly and safely.
Fig.6 Smart textile for militery

Military textile
3. FASHION AND ENTERTAINMENT
Club wear that reacts to movement, heat and light. They include garments with panels that illuminate when the dancer moves, or clothing that contain fibre optics woven and integrated into the fabric.

… The development of high-tech advanced textiles for initial high-value applications such as extreme sports will eventually find its way into street fashion, with designers employing their creativity to use these emerging materials in new ways. We are becoming increasingly reliant on technology carrying MP3 players, laptops, mobile phones and digital cameras. These devices all contain common components such as power supply, microprocessor, data transmission. As the technology is becoming more flexible these could ultimately be integrated into a common textile substrate - our clothes, becoming truly portable devices. Already there are textile switches integrated into clothing for the control of such devices. While technology may be hidden through invisible coatings and advanced fibers, it can also be used to dramatically change the appearance of the textile, giving new and dazzling effects. Light emitting textiles are finding their way onto the haute couture catwalks, suggesting a future trend in technical garments. the haute couture catwalks, suggesting a future trend in technical garments.

Fig.7 Smart fabrics for entertainment & fashion
4. SPORTSWEAR
Sports enthusiasts are able to benefit from integrated fabric sensors and display panels. They monitor heart rate and blood pressure during a gym workout or morning run and are able to analyse the information giving feedback on performance along with playing mood/ performance enhancing music.

Some sports clothing such as car and motorbike racing and also astronauts suits contain integrated electronics Components.

5. PURPOSE CLOTHING
  • Global Positioning Systems (GPS) incorporated into walking shoes which allow the user to be tracked by mountain rescues services. In Ski jackets to help locate the wearer in the event of an avalanche.
They can also used to monitor the where about of young children.
  • Gloves that contain heaters, or built in LED’s emitting light so that a cyclist can be seen in the dark.
6. TRANSPORT AND AUTOMOTIVE USE
  • Modern contemporary cars contain control panels that activate heated seats, air-bags.
  • Transport and automotive industries is one of the largest that benefits from interactive electronic and technical textiles. They have uses in space shuttles, aircraft and racing cars.
FUTURE DEVELOPMENTS
Further developments in interactive and wearable electronics include garments and clothing that contain Lumalive textiles that are able to transmit messages/advertisements. They have the ability to change colour, and contain LED’s incorporated within the clothing. Phillips the electronics company behind these latest innovations is planning to develop fabrics with Lumalive technology that will allow soft furnishings such as cushions, curtains etc. to transform/ alter colour and illuminate consecutively enhancing mood and atmosphere of their surroundings.

To take the next step towards electronic clothing (made of electronic textiles) research has to be carried out in the following areas:

Clothing technology for manufacturing testing under wearing conditions and washing/cleaning treatments investigation of reliability We have seen that electronics can not only be attached to textiles but also realized in form of textile structures. Today, some performances cannot be compared with conventional computer technology. There are also some limitations concerning mass production and reliability. In the future it could become quite difficult to clearly separate electronic textiles from the aforementioned method of miniaturization plus attachment, because computers could be miniaturized until they are molecule-sized. In this case ‘attachment’ to fibres or fabrics would also lead to what we define as electronic textiles.

Plastic was a revolution, and nano-technology will probably be the next big change. There are a lot of thoughts about what could be done if we were able to manipulate, rearrange and build from molecules and atoms. Having a machine that changes a bicycle tire into meat, self-cleaning carpets, changing state from rigid to flexible and visa versa.

REFERENCES:
  1. L.van langenhove , smart textile for medicine and health care: material system and application,woodhed publishing limited Cambridge, England
  2. Wearable Intelligent Systems for E-Health Carmen C. Y. Poon and Qing Liu Joint Research Centre for Biomedical Engineering, Department of Electronic Engineering, The Chinese University of Hong Kong, Hong Kong SAR
  3. Smart Fabrics and Interactive Textile Enabling Wearable Personal Applications: R&D State of the Art and Future Challenges. Lymberis, R. Paradiso.
  4. Interactive Sample Book (ISB) – An Inspirational Tool for Smart Textiles Authors: Elisabeth Heimdal, Torben A. Lenau, Michel Guglielmi and Hanne-Louise Johannessen
  5. Smart fabric & interactive textile wearable systems Prof. Danilo De RossiInter departmental Research Centre “E.Piaggio”University of Pisa.
  6. Microsystems and Smart Integrated Systems: A key enabling technology for AAL Dr Andreas Lymberis andreas.lymberis@ec.europa.eu
  7. 2005. Axisa, F., Schmitt, P., Gehin, C., Delhomme, G., McAdams, E., & Dittmar, A. (2005). Flexible technologies and smart clothing for citizen medicine, home healthcare, and disease prevention. Information Technology in Biomedicine, IEEE Transactions on , 9 (3), pp.325-336. doi: 10.1109/TITB85450.
  8. “Textile review journal january 2011” smart textile by Dr.anita nishkam,Dr.lokesh shukla.
  9. “Man made textile in india journal”August2011 ,development of E- monitoring garment by A.s.joshi,K.sharma D.wagh and D.pareek.
  10. Conductive textiles for smart fabrics by N.v. bhat, D.t.sheshadhari,M.m.nate and A.v.gore.
  11. Technical textiles international octomber 2011,wearables help develop a sixth sense for saftey and protection by Adrian wilson.
  12. Intelligent Textiles, Soft Products Carl André b Department of Product Design NTNU, Norwegian University of Science and Technology.
  13. Interactive Sample Book (ISB) – An Inspirational Tool for Smart Textiles Authors: Elisabeth Heimdal, Torben A. Lenau, Michel Guglielmi and Hanne-Louise Johannessen.
  14. Addington D.M. & Schodek, D.L. 2005, Smart materials and technologies: for the architecture and design professions. Architectural press Oxford.
  15. Pasta newsletter 7th framework program. July 2011.Johan De Baets johan.DeBaets@imec.be
  16. H.S. nalwa, handbook of organic conductive molecules and polymers, volume 1-4, john wiley, new York 1997.
  17. E. hellwag e-textiles come into style: http://www.technologyreview.com.
  18. Websites http://web.media.mit.edu/~rehmi/fabric/ http://en.wikipedia.org/wiki/Smart_textile
  19. www.google.com http://pg01-fashion-tanvi.blogspot.com/2009/10/smart-fabrics-hi-tech-textile.html
  20. Technical presentation of Itech10,November 24,2010 HOFMANN congress park hanau, germany.  
 

Concepts of Knit Garments Merchandising


CONCEPTS OF KNIT GARMENTS MERCHANDISING
M.R. Karthikeyan, 
Expatriate Lecturer in Textile Engineering,
Kombolcha Institute of Technology, 
Wollo University, Ethiopia
Email : srimrk@yahoo.com





Introduction:
Merchandising denotes all the planned activities to execute and dispatch the merchandise on time taking into consideration the 4 R’s of expediting Right Cost, Right Quantity, Right Quality and Right Time.

Functions of Merchandisers:
  1. Execution of Sample orders
  2. Costing.
  3. Programming.
  4. Yarn Procurement Arrangements.
  5. Production Scheduling (or) Route CARD Drafting.
  6. Accessories arrangement (order placing follow-ups).
  7. Approval of various processors’s sewing operations and finishing processes.
  8. Pattern approval (or) Dummy size set approval.
  9. Size set approval.
  10. Preproduction sample follow-ups.
  11. Pilot run inspection.
  12. In process inspection.
  13. Production controlling.
  14. Identifying shortages and make arrangements for the shortages.
  15. Shortage quantity and quality following quality control procedures.
  16. Following quality assurance procedures.
  17. Maintaining the junior’s activities of in house and sub-contractor units.
  18. Buyer communication.
  19. Communication with production units, processing units and other third party’s (vendors).
  20. Proper reporting.
  21. Highlighting to the management.
  22. Record maintenance (Records pertaining to merchandising).
  23. Developing samples.
  24. Placement of orders.
  25. Taking measures for consistent production.
  26. Taking preventive actions to maintain the targeted Performance level in all areas of merchandising.
  27. Attending meetings with superiors and furnishing the required details about merchandising.
1. Sample order execution:
After the receipt of the Specification, pertaining to the sample order, the merchandiser has to
understand what the requirements of buyers are. Sometimes there may be amendments related to any of the specifications in the sample order sheet. It is the duty of the merchandiser to execute sample order and dispatch on time the “Right quality.”
Knit garment
2. Costing:
The merchandisers should know the following details while costing.
  • Yarn cost.
  • Process cost (Knitting, Bleaching, and Raising etc.)
  • Rates pertaining to various sewing operations.
  • CMT(Cut Make Trim) Rate.
  • Ironing charges, packing charges and accessories rate.
  • Overheads.
  • Shortage (or) wastage 3%.
  • Free on Board (FOB) (Transport charges) 2% to 3%.
  • Insurance 2%-3%,
  • Buyers’ agents commission 5%-6%,
  • Quota rate per garment.
  • Profit 15% - 20%
3. Programming:
Most probably programming is done by production manager. In some companies it is done by the
merchandisers. The following factors should be considered in programming.

1. Allowances:
  • Fabric structure
  • Dia. fixation (knitting dia., calendaring dia. and compacting dia.)
  • Process loss (shrinkage etc.)
  • Size wise piece weight
  • Extra quantity required
  • Size wise requirement (dia., colour (or) combination)
4. Route card Drafting (or) Production Scheduling:
For each and every order Route card (or) Production scheduling is to be done by the merchandisers. It facilitates the merchandiser to follow up the orders in planned manner. The following details (or) aspects should be considered in drafting (or) scheduling.
  • Design
  • No. of sewing operations
  • No.of processes
  • Despatch date
  • No. of Components
  • Type of stitches
  • Order quantity
  • Production capacity of the in houses (or) sub-contractors unit and processing units.
  • Prioritizing the other factors
  • Targeted dates for various processes (or) stages of merchandising.
  • Actual finishing date (To cross check the deviation between the planning and actual performance any stage (or) Process). Targeted dates for all the stages of merchandising should be decided. Actual dates on which a particular process (or) operation is actually done should also be entered in production scheduling. The merchandisers are accountable for the deviation.
5. Accessories arrangements:
Merchandiser has to make arrangements for the timely delivery of the required accessories to the
concerned units. Accessories requisition slip may be used for requirement purpose. The merchandiser has to cross check the actual requirements after verifying the details furnished in accessories requisition form. After the receipt of accessories quality check will be done.

6. Approvals:
Approval is an authentication of all required conformances related to a process (or) an operation. The merchandisers should know the quality parameters of various processes and sewing operations before approvals. There should not heron-conformities. Evidences for approval should be cross checked to confirm that all the approvals having made properly.

7. Approval of various processes sewing operations and finishing processes:
The various process of sewing operations and finishing process such as patter making, cutting,
sewing, ironing will be approved by the technical merchandisers

8. Pattern approvals:
Patterns should be approved for
  • Measurement
  • Style and fit
  • Allowances
  • Accuracy of pattern
If there is any non-conformance in pattern that should be corrected before it is used in production
Pattern approval samples will be received from the concerned units and approved by the approval
department (or) merchandisers, If there is non-conformance in any size sample revised sample for that size should be again submitted for approval.

9. Size set approvals:
Size set approvals are made by the approval department or) by the merchandisers. All the quality
parameters related to various processes, sewing operations have to be cross checked. The below
mentioned aspects should be considered.
  • Measurements
  • Aesthetics
  • Process quality
  • GSM
  • Piece shrinkage
  • Washing fastness of the piece
  • Sewing operation quality
  • Print (or) embroidery position
  • Labeling instructions.
  • Size set approval seat will be prepared in triplicate.
  • Washing fastness of garment should be verified.
  • Shrinkage in garment can also be verified.
10. Pre-production samples:
This samples should he submitted on time to the concerned person (Buyers, buyer agents office
buying office). All the quality parameters have to be verified. In case of non-conformances it will be
mentioned in the approval sheet by the concerned persons. Sometime we may have to submit the
revised samples after the required rectifications.

11. Pilot run inspection:
Pilot run denotes the first production garments quality parameters are verified and preventive
measures can be taken. The follow up team should do pilot run inspection to identify the various
defects and it will be rectified in production.

12. In process inspection:
In process means in between any process (or) sewing operation (or) any activities related to execution of an order. We can have procedures for frequency and adequacy. In case of major non- conformities we have to highlight the problems of quality at the right time to the right person without fail. Consistent follow up inspection is a must to confirm that all the required quality procedures are adopted by the concerned units and preventive actions are taken to enhance the performance.

13. Production controlling:
Controlling should be right from the operative level also. Efforts should be taken to control the nonconformities during production. Consistent supervision is essential to control the non-conformances. Periodical quality check should be done after an hour.

14. Shortage problem:
The merchandiser has to identify the shortages of any material that is yarn, fabric, accessories etc. right at the initial stages. After identifying the shortages steps are to be taken for the arrangement of required materials on time. In case of shortages also we have to follow the quality control and quality assurance procedure without fail. Quality of the material should not be compromised.

15. Following quality control procedures:
In some companies written quality procedures are available in quality manual. The merchandiser has to know all the procedures of quality control. In all processes and operations quality procedures should be followed very strictly. It has to inculcate the importance of procedures to subordinates, in house units (or) own units, and sub contractors.

Following quality assurance procedures:
All the required test procedures (as required by the buyer) should be followed very strictly without
partiality. Evidences for testing (test reports) tested samples, tested swatches, tested accessories) should be maintained properly. Before cutting, the merchandiser has to confirm that the concerned unit has got all the required approvals properly from the authorized person.

16. Monitoring the junior activities:
The merchandiser has to monitor his sub-ordinates. He has to teach to the subordinates about the quality procedures. He has to give instructions to them before going for factory visits. He has to discuss the various activities to be executed on a particular day. The merchandiser has to control the activities of the subordinates so that the performance of the followed team is good.

17. Monitoring the activities of in-house unit (or) sub-contractor units:
The merchandiser has to monitor the activities of in-house unit (or) sub-contractor units. He has to confirm that all the quality control procedures and quality assurance procedures are followed up properly by them (or) not. He has to inculcate the importance of adopting quality procedures to attain the planned performance level.

18. Buyer communication:
The merchandiser has to go through the faxes coming from buyers and he has to send reply on time. Sometimes he has to furnish the production status of a particular order to the concerned buyer on time. The below mentioned are some of the duties of buyer communication,
  • Sample execution
  • Amendments
  • Comments on the send samples
  • Sample order sheet
  • Buyer visit
  • Production status
  • Sending sample, swatches, Accessories regarding the approvals.
19. Communication with others:
The merchandiser has to interact with in-house units, sub-contractors, vendors and job workers of various processing. Through proper interaction only we make arrangements for the timely supply of the required materials to the concerned persons. He has to know the production status from various units which will be helpful in proper follow and proper importing.

20. Proper Reporting:
The merchandiser has to furnish (or) best the report to the right person at the right time. He has to give reports for the below mentioned activities
  • Sample execution
  • Approvals
  • Testing procedures
  • Production status
  • Programming
  • Shortage details
  • Inspection details arid status.
  • Production status for meting etc.
  • Report from inspection agencies, testing labs
21. High Lighting:
The merchandiser has to highlight the major problems in merchandising at the right time without fail. Highlighting will facilitate the superiors to take the necessary steps to tackle the problems on time. Proper decision is made due to timely highlighting.

22. Record maintenance:
The merchandiser has to maintain quality records pertaining to various buyer orders. Proper filing should he done, who can utilize the services of subordinates in record maintenance. The below mentioned are some examples.
  • Sample details
  • Sample Inspection Reports
  • Testing Reports
  • Evidence of approvals
  • Proper filing (Buyer wise, order wise)
  • Pattern Approval sheet/size set approval sheet (copy)
  • Pilot run Inspection Report
  • Fabric Inspection report
  • Mid Inspection Report
  • Inspection report from buying office, buying agents and inspection agencies.
  • Test reports from inspection agencies and labs
  • Production status reports
  • Production status reports related to meetings
  • Pre-final inspection reports
  • Final inspection reports etc.
23. Developing samples:
Some buyers will give specifications (or) diagram (or) patterns from which you may have to develop samples. Samples may be fabric with required knit structure (or) garments with required specification. The merchandiser has to consider all the quality parameters related to the samples to be developed. In case of non-conformities in the samples developed, revised samples may be send for approval purpose. It is the duty of the merchandiser to dispatch the developed samples on to the concerned buyers by means of consistent follow-up.

24. Placements of orders:
Priority is given to Approved sub-contractors after evaluation (when the production capacity is not sufficient) order is placed to new manufacturers also orders can be placed to in-house units also. In some companies, merchandiser is accountable (or) responsible to find out the right manufacturers after proper evaluation. At the initial stages small quantity order will be placed. After verifying their performance large quantity orders will be placed. Yarn may be procured by the concerned unit (or) it may be supplied by the supplier (the main manufacturer). In case of CMT order after the confirmation of average piece weight of a particular size, processed fabric is delivered to the concerned unit by the supplier.

25. Taking measures for consistent production:
It is the duty of the merchandiser to monitor the merchandising activities in accordance with the production scheduling. He is accountable for the execution of each and every process (or) an operation within the targeted time. He has to take the necessary step for the consistent production by tackling the problems in merchandising. (e.g.)
  • Quality of yarn
  • Replacing good quality yarn
  • Consistent arrangement for fabric
  • Timely arrangements for the timely supply of accessories.
  • Shortage quantities follow up.
26. Preventive actions:
Detection of defects is not only the duty of merchandiser. He has to take preventive actions to eliminate deviations in all the stages of merchandising.

27. Attending meetings with superiors:
Meetings may be conducted for general discussions about order execution (or) for implementing new systems like ISO (or) it may be a status meeting. In case of production status meeting the production details about various buyers’ order will be collected by the merchandiser from different units and will furnished to superiors. The merchandiser is accountable to answer the various questions raised by the superiors pertaining to the execution of the allotted orders.