What makes the difference – “the Future” in Operations

  1. SIX STORIED PRODUCTION FLOORS WITH 105,000 SQFT AREA.
  2. FULLY INDUSTRIAL ENGINEERING BASED PRODUCTION SYSTEM.
  3. TOTAL MONTHLY CAPACITY PRODUCTION OF 250,000 PCS SWEATERS.
  4. FULLY AUTOMATED & JACQUARD FACILITY –SHIMA SEIKI & STOLL JACQUARD MACHINES FROM JAPAN & GERMANY.
  5. INHOUSE R&D (FUTURE EXPANSION PLAN), FASHION DESIGNER CREATING OVER 60 ORGANIC DESIGNS/MONTH. SYMATRONIC DESIGN SYSTEM, APEX4 HYPER VIRTUAL STUDIO CLO3D AND VIRTUAL SAMPLING.
  6. MOST ADVANCED HIGHSPEED DIAL LINKING & AUTO SUPER LINKING MACHINERIES.
  7. PROCESS EXCELENCE-- OPTIMIZING MAN/MACHINE RATION, FAST TRACT MODULES FOR SPEED & FLEXIBILITY.
  8. STRONG MID LEVEL MANAGEMENT, CAPACITY MANAGEMENT, LEAD TIME ASSESSMENT, CRITICAL PATH MANAGEMENT, UNCOMPROMISED ATTITUDES TOWARDS PRODUCT QUALITY, SAFETY, CONFORMITY & DELIVERY DECIPLINE.

The all out weather & fashion items we are making

  1. All kinds of Pullovers, Cardigans, Jumpers, Leggings, Hats, Scarves, Mufflers, etc in Fancy, Jacquard & Jacquard Intarsia Knitting with latest design module from 1.5 gg to 14 gg.
  2. Piece/garment dye, Pigment dye, Acid wash, Stone wash, Enzyme wash, Space dye, Top dye, Dip dye, Tie dye.
  3. We also got expertise to do set styles like sweater packed with shirt/T-shirt/Tights/trouser or integrated with outerwear/Active wear/blazer styles which are more into fashion now.
  4. We are focused in whole garment/seamless sweater production trial run and future expansion.
  5. We are focused in whole garment/seamless sweater production trial run and future expansion.

Our Capability - Sweaters

Pullovers; Cardigans; Jumpers; Leggings, Hats, Scarves, Mufflers, etc
  1. In Fancy, Jacquard & Jacquard Intarsia Knitting and hand crochet.
  2. In Piece dye, Pigment dye, Space dye, Top dye, Dip dye, Tie dye
  3. In Acid wash, Stone wash, Enzyme wash, Rubber Ball wash, etc
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Capacity & Projected Expansion

YEAR 2023
Machine Type GG No of Machines Capacity (pcs/month)
AUTO/JACQUARD 1.5/3 GG 20 30,000
AUTO/JACQUARD 7-14 90 100,000
AUTO/JACQUARD 3-7 140 170,000
TOTAL 250 300,000
Future Expansion Plan
Year Machine Capacity (Pcs/ month) Revenue (M/USD)
2023 250 300,000 20
2024 1000 12,00,000 65
2025 1500 18,00,000 100
2026 2500 30,00,000 165

Roadmap for KEY Performance Objectives

KPI

KPI measures the key role of each employee of Global Merchants Ltd.
It would help to achieve organizational goals & Objectives.

Continuous Improvement

Global Merchants focusses continual improvement of Products, services and Process.
For Quality Improvement, QA team will prepare CAP & this will be monitors in the process and product improvement and monthly basis will be shared in the monthly performance meeting.

Technology Transformation

Automated technology would be adopted in all areas to improve the overall efficiency:

  1. High speed dial linking
  2. Auto Super Linking Machine.
  3. Quality Digitalization
  4. Lean system
  5. RFID Tracking system to reduce WIP.
  6. Automation in the make up (linking to finishing) to enable uninterrupted production in knitting to finishing lines.
Industrialization

Global Merchants IE team work closely in areas of costing, SMV calculation, setting targets, production management, process optimization & reducing all the 7 waste.
Global Merchants Ltd’s has a strong Production planning and capacity management team. The Capacity Management Team is worked hands in hands with Production and Marketing/Merchandising Department to avoid any over commitment, production backlogs and ensuring the delivery discipline.



Roadmap for Quality Objectives

In Coming Control (Yarn, Accessories & Trims)

Objectives : to Control the In-coming defects

Road to Objectives:
  1. SOP Practices
  2. Yarn, accessories & trims quality and color check.
  3. Non-confirm goods management
  4. Test Report
  5. Skill Matrix
  6. KPI
Knitting

Objectives: To control the Knitting defect & Yarn wastage Control.

Road to Objectives:
  1. SOP Practices
  2. Producing Right at first time in Knitting.
  3. Non-confirm goods management
  4. Defect Analysis
  5. Skill Matrix
  6. KPI
Linking

Objectives : To control the Defect rate by continuous improvement and increase efficiency

Road to Objectives:
  1. SOP Practices
  2. Producing Right at first time in Linking.
  3. Non-confirm goods management
  4. Defect Analysis
  5. Test Report
  6. Worker environment
  7. 5s/good house-keeping
  8. Risk analysis
  9. Defect traceability
  10. Skill Matrix
  11. KPI
Finishing

Objective : to Packing the goods which are confirmed.

Road to Objectives:
  1. SOP Practices
  2. Producing Right at first time for inspection
  3. Non-confirm goods management
  4. Metal Detection
  5. Defect analysis
  6. Skill Matrix
  7. KPI

Roadmap for Real Time Information System

SL Objectives Target Groups
1 Efficiency Reports Individual, Line, Department, Factory
2 Lost Time Control All Sections
3 WIP Tracking All Orders
4 Running Line Balance Position WIP levels on all Operations
5 Bundle Tracking Late Bundles, Problem Bundles
6 Attendance All Sections
7 Quality Information Per Operator, Style, Operations, Line
8 Bottlenecks Lines
9 Skills Matrix Automatically Updated
10 Incentive Earnings Lines and Operators

Roadmap for Compliance Objectives

Factory is targeted for completing the below compliance certifications to qualify the buyers in different regions:
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Targeted Customers & Partners

Factory would be ready with quality and performance standards to serve the below renowned buyers in different regions:
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Design and Product Development Bangladesh, Spain & UK

  • Creating organic designs, seasonal trend direction, mood boards, color palette, latest silhouettes, yarn/fabric & lace directions.
  • Guiding toward latest yarn and fabric trends ahead of the buying seasons through visits to the key trade fairs in both Europe and the Far East (Pitti Filati, Spin Expo, Etc)
  • Ready to offer a bespoke service to all customers in-line with their requirements; from color swatch work, knit downs, stitch and yarn intelligence to creating a full seasonal design collections.
  • Working closely with retail buyers and designers to ensure designs are commercial and appropriate for the brand.
  • Continuing to invest in the latest technological innovations and advancements in the area of product development to offer our customers the most up to date service and benefits; for example, virtual sampling & development of seamless sweater or whole garment in Bangladesh market.

Research & Development

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We are commited towards sustainable manufacturing

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