Carte Blanche

A Corporate Milestone of Quality and Commitment

Faa Apparels Ltd.

Joynabari, Hemayetpur, Savar, Dhaka.
 BRIEF ON FAA APPARELS LTD.

Introduction

1. Faa Apparels Limited was established in 1992. To cope up with the post MFA challenge, the
company constructed a new factory complex at Hemayetpur. This is a location just at the western
outskirt of Dhaka city – on the way between Dhaka and Savar. The factory site is at about 200 yards
north-west of Hemayetpur tri-junction, on the northern side of the main road. The complex is bounded
by perimeter wall over 3 acres of land having two separate entry and exits from the main road.

Physical Features

2. Size. The factory activity is spread over 4 floors. Each of the floor size is of 32,000 sq ft.
However, we are utilizing only 14,000 sq ft each from the Ground and Top floor at the first stage. That
is how, the factory size stands at 92,000 sq ft at this stage. We are also planning to utilize the
remaining portion within a near future. Thus, the factory will be of 1, 28,000 sq ft in total.

3. Floor Layout. Over the said 4 floors at stage 1, the departments are placed as per following:

a. Ground Floor – 14,000 sq ft.

* Raw materials store

* Office Complex and Personnel Department

* Reception and waiting room

* Jute room

* Sub station and generator room

b. 1st Floor – 32,000 sq ft.

* Cutting department

* Finishing department, Boiler room and Buyer Inspection rooms (2 rooms)

* Quality Management’s office

* Medical Inspection room and 4 bed Mini Hospital

* Child Care room

* Lavatories
 c. 2nd Floor – 32,000 sq ft.

* Sewing department

* Production Management’s office

* Sample Department

* Maintenance Department

* Production Account

* Lavatories

d. 3rd Floor – 14,000 sq ft.

* Dining Room

* Empty cartons and containers store.

4. Production Lines. At this stage, the factory has nine (9) production lines with 1374
workforce to work in one shift only. By next few months, more 2 lines will be added to make it an 11
lined factory.

5. Capacity of the Factory. By 9 lines, the factory can produce following quantity of
garments:

* Monthly Capacity: 2,25,000 pcs

* Yearly Capicity: 2.7 Milion pcs

The production capacity will be increased by 20% when more 2 lines will be set up in the next
phase.

Products

6. Production Standard. As going on now, the company produces a variety of high quality
woven items. Using modern machinery along with the guidance of related experts, the factory is made
to reach the Top End in terms of quality.

7. Product Categories. Following are the product categories that the factory is capable of
manufacturing:

Men Woven Shorts / Trousers / Jackets / Shirts

Women Woven Trousers / Skirts / Jackets / Shirts / Blouse / Slacks
Boys Woven Shorts / Trousers / Shirts / Jackets
Toddler Baby Woven Shorts / Trousers / Slacks / Shirts
Marketing

8. Our Present Customers. For our facility, we have targeted the valued buyers who ask for
compliance and even fulfilling CTPAT requirements too. In our existing floor, we had been working for
the following buyers / brands:

a. Costco

b. Dickies

c. H & M.

d. HBC

e, Target Corporation

Economic Information

9. Business Turnover. Our yearly business turnover in the initial stage is about US$ 12Millions.
However, it will be US$ 15 Millions in the subsequent stage.

10. Bank. Our banking is done with the following bank:

National Bank Ltd.

Mohakhali Branch, Dhaka.

Equipment & Machinery

11. A machinery list is given at Annex A.

Organization

12. An organization chart of the factory is given at Annex B.

Compliance Aspects

13. The company gives top priority in observing the compliance drills. Employees’ welfare is
looked after with special care. Health and hygienic aspects are given due importance. Labor laws are
followed in full. Safety aspects of the workers are given top priority. Maternity benefits are ensured for
all concerned females as per law of the land. Salary and other benefits including leave are given to all
according to the existing system of the country. Environment purity aspect is also given due care.
Contacts

14. Contact Persons.

Atiqur Rahman Munna : For Marketing and Sales

Niaz Ahmed Jaber, psc, MBA : For Operations

Bashir Haider : For Commercial & Banking

15. Company Contact E-mail ID.

Company contact E-mail for further inquiry: munna@carte-blanche.biz

jaber@carte-blanche.biz

Company contact phone for further inquiry: 880-2-7713797, 880-2-7713959.

16. Factory Address. Joinabari, Hemayetpur, Savar, Dhaka, Bangladesh.

 Annex A

List of Equipment / Machinery

Sl Machine Type Brand / Model / Average Age Quantity Remarks

Specification

Sewing Machinery
1. S / N (Light) Brother SL1010 - 1 3 years 60
2. S / N (Med) JUKI DDL 8300N 3 years 310
3. S / N (Heavy) Brother SL1010 - 5 3 years 40
4. S / N (UBT) Brother S 7200A 3 years 48
5. S / N Edge Cutter JUKI DLM 5200N 3 years 22
6. D /N (Med) T 8420B 003 N64D 3 years 35
7. D /N (Heavy) T 8420B 005 N64D 3 years 20
8. O / L – 4 & 5 Thread MO6716 SFF6 60H 3 years 90
9. Kansai DFB - 1404 PSF / 3 years 13
DFB - 1404 PMD
10. Feed of the Arm (N) DA 9270--264X 3 years 10
11. Feed of the Arm (Hy) DA-9280-D-364X 3 years 20
12. Button Hole LBH-781 / HL-4B-814-2 3 years 10
13. Button Lock Stitch LK1903ASS301 / 3 years 10
MC596KSS
14. Flat Lock (Loop Maker) B 2000 C 3 years 2
15. Bartack (Comp) LK1900AHS 3 years 12
16. Bartack (Normal) Brother LK-3-B430 3 years 3
17. Blind Stich 2 years 1

Finishing Machinery
18. Eyelet S 211 CT 3 years 2
19. Snap Button YM 160 / PP5600ZP 3 years 30
20. Thread Sucker NS-54 3 years 2
21. Light Box CAC 60 3 years 1
22. Vacuum Table (w ht) NS 3522 3 years 24
23. Spot Remover NP 978 3 years 1
24. Button Pull Tester SafQ 2 years 1
25. Needle Detector Cintex 2 years 1

Cutting Machinery
26. Cutting Machine 8’’ KS-AU-V-8" 3 years 3
27. Cutting Machine 10’’ KS-AU-U-10" 3 years 3
28. Fusing Machine HP900LCS 3 years 1
29. Fab Inspection M/C NS-58L(72’’) 3 years 1

Other Machinery
30. Generator Set 275 KVA SCANGEN 3 years 1

31. Pneumatic Compressor 10 SP 2 years 1

 Annex B

Organization Chart of the Factory

Production Floor

Department Sanc Remarks Department Sanc Remarks

Strength Strength
Sample Department Cutting Department
Sample Manager 1 Cutting Manager 1
Sample In-charge 1 Cutting In-charge 1
Pattern Master (CAD) 1 Supervisor 2
Pattern Master (Gen) 2 Cutter Man 6
Supervisor 1 Marker Man 2
CAD Operator 2 Cutting Machine Helper 3
Kansai Operator 1 Lay Helper 12
Button Stitch Operator 1 Bundling & Card Writer 6
Thread /Leg Panel/Mock up 1 Number Printer 2
Store Coordinator 1 Numbering Helper 10
Sample Cutter 4 Hand Cutter 12
Sample Operator 14 5% will be Pin up Man 4
Finishing Man 2 recruited Fusing Machine Helper 3
Helper 4 additionally Servicer 2
QC Auditor 2 QA (Fabric) 1
Total 38 QA (Cut Goods) 1
QC (Fabric) 1
Sewing Department QC (Cut Goods) 6
Production Manager 1 Total 75
APM 1
Senior Line Chief 2 Finishing Department
Line Chief 7 Finishing Manager 1
Supervisor 27 Finishing Sec In-charge 2
Operator 540 5% will be Packing In-charge 1
Helper 310 recruited Supervisor 6
additionally
Servicer 9 Iron Man 20 3% will be
QC In-charge 1 Iron Helper 20 recruited
Quality Auditor 4 Folding Man 12 additionally
QC 50 Hang Tag Man 5
Total 952 Poly Packing Helper 5
Button Stitch Operator 10
Maintenance Section (Garment) Alter Operator 4
Mechanical In-charge 1 Alter Helper 2
Mechanic 6 Thread Cutting Helper 15
Mechanic Helper 3 Button Marking Helper 10
Boiler Operator 2 Packing Man 12
Total 12 Servicer 2
Qual Insp In-charge 1
Miscellaneous QA 6
Factory Manager 1 QC 48
QC Manager 1 Total 182
Total 2
Grand Total: 1261
 Administration Division

Department Sanc Remarks Department Sanc Remarks

Strength Strength
Maintenance Dept (Elec & Mechanical) Personnel Department
Asst Maintenance Manager 1 Personnel In-charge 1
Electrical In-charge 1 Compliance Officer 1
Electrician 5 Personnel Officer 3
Electrical Helper 2 Counseling Officer 1
Plumber 1 Time Keeper 1
Welder 1 Clerk 1
Welding and Plumbing Helper 1 Office Executive 1
Total 12 Office Assistant 1
Total 10
Health & Safety Department
Garment Store Medical Officer 1
Store In-charge 1 Fire Safety Officer 1
Store Officer 1 Nurse 1
Store Keeper 2 Child Care Attendant 2
Computer Operator 1 Total 5
Store Assistant 2
Needle Supplier 2 Production Account & Planning Department
Store Helper 4 In-charge 1
Store Loader 8 Computer Operator 1
Total 21 Production Counter 4
Asst Production Counter 2
General Admin Helper 2
Admin In-charge 1 Production Planner 1
Security Officer 1 Time Study In-Charge 1
Guard Commander 3 Time Study Staff 1
Security Guard 12 Total 13
Lady Security Supervisor 1
Female Checker 6 Miscellaneous
Admin Super 1 GM (Operations) 1
Driver 3 Network Engineer 1
Tel Operator 1 Accounts Officer 1
Peon 2 Cashier 1
Gardener 1 Total 4
Sweeper / Cleaner 16 Grand Total 113
Total 48 Overall Grand Total 1374
 Factory Pictures

Front View & Lobby

The factory welcomes you with a spacious entrance having a

colorful fishpond and a fountain at the lobby
 Safe Passage

Sufficiently wide 4 stair cases at 4 corners and necessary

walkways provide safe passage to the workers and visitors to
move smoothly in case of any emergency.
 Cutting Section

In the cutting section, use of metal hand gloves and adoption of

other safety measures by the workers are the compulsory affairs
of the factory.
 Sewing Section

Neat & clean sewing floor makes the workers work comfortably in
a homely environment.

Sewing Quality

In the Sewing Section, each garment is checked piece by piece

and special care is taken for white fabrics.
In the above picture, this production line has been separated from
other lines by white curtain to keep the garments dust free.
 Ironing Section
Sewing Quality

Ironing Section’s steam irons get steam supply from a 250 kg

boiler installed at outer corner of the floor.
 Finishing Quality

Goods at the Finishing Section are checked one by one to ensure

quality production.
 Packing Section

Packing Section having mat on the floor and racks to

stake the finished goods ensures freshness of the final
product.
 Sample

Sample Room makes customers choosing production friendly

samples suiting with the buyers’ requirements.

Special Machinery

Special machinery is used to make the product quality perfect.

 Safety & Hygiene

Various points and places like fire extinguisher points, toilets etc
are kept clean at all times.

Safety, Health & Hygiene

First Aid boxes are posted at various places of the floor. Female
toilets are totally separated from the male toilets.
 Safety, Health & Hygiene

Dining room is kept clean and pure drinking water is provided for
drinking.

Welfare

Medical room is established to provide medical support to the

workers during at work.
 Welfare

Child Care Room has been established in the factory to provide

relief to the working mothers.
 Power Backup

Own sub station and generator provide power backup to the factory
during the normal power failure time.