Apparel Online Bangladesh Magazine Magazine May 2018 | Page 25

EXPORTER STRATEGY
The infusion of the latest automated
technologies is also helping the
company to maintain the quality
desired by the buyers and that too at
a much lesser cost than the market
price. This makes Delta a trusted
company in the market in an era
where most of the manufacturers are
cribbing about losing orders due to
their failure at keeping the unit prices
of garments low and, at the same time,
to be able to maintain a high quality
level.
According to Rupak, the entire
operations, right from cutting to
packaging, are automated in the newly
developed Delta Denims. The cutting
division has spreaders and cutters
from BOK which is a leading Chinese
player in this segment, making the
cutting process both efficient and
effective. “Though, in the market,
there are other renowned brands too
in the cutting segment, my decision of
opting for BOK is paying dividend to
me as I am able to save at least 30 per
cent cost in cutting division today,”
claims Rupak.
Further, the company has carved a
niche for itself through a gamut of
Euromac jeans automats as Delta’s
production floor constitutes 88 sewing
lines and each line has around 54
machines. “We have a capacity to
produce 2500 - 2800 pieces of jeans
per day per line,” shares Rupak
stating that with manual intervention,
the company would have needed 65
workstations with at least 14 helpers
while currently it is operating on just
54 workstations with just 4 helpers,
saving the cost of 11 workstations and
manpower which is commendable.
Delta Denims has automised the
packaging division too where final
packing of the garments is done by
blowing air in poly bags. Hence this
division of the company is also saving
the cost incurred on humans.
Besides, Delta will invest US $ 1,00,000
in ERP in order to strengthen its
production and washing planning of
88 sewing lines.
The benefits that Delta is reaping
today are surely going to increase
once its two new garment units
become fully operational. However,
installing technologies and bringing
the best out of that has never been
an easy task for the company.
Explaining the company’s view point
Delta has installed laundry machines powered by Tonello and Yilmak
of investing so much in automation,
Rupak comments, “As we are a new
entrant in denim, it was important
for us to have advanced technologies,
otherwise we won’t be able to compete
with the renowned and already
existing denim factories which are
more than 20 years old in Bangladesh
and plenty in number.”
Unconventional yet
enticing shopfloor
practices making Delta
surge ahead
With the way business is shaping up
in Bangladesh, the factory owners
are inclining more towards the
concepts which help in improving
shopfloor management as well as
efficiency. Going one step ahead, Delta
is utilizing the available data in the
most optimum way as it believes that
the systematically arranged data can
help the company become better in
pre-production planning stage, and
thereby in the subsequent processes.
Taking a different route from the
conventional practice where a
merchandiser handles the data entry
task of a new garment order, Delta has
hired a ‘Business Analyst’ to enter the
data in its ERP software. Rupak, in
a confident tone, explains, “Suppose
you have the following data – 10,000
pieces of Inditex, Bottoms, SMV 15
Corporate
Social
Responsibility
• Delta conducts
10 minutes’
treadmill
running
session for
mid-and top-
management
on a daily basis
for their mental
and physical
relaxation.
• There are
daycare centres
for the children
of female
workers in
Delta Group.
minutes, delivery date 60 days from
today. As per standard practice, the
data is fed in the software and then
we know if it is telling us the right
times lot of accomplishing the order
within the next 60 days. It will tell us
the available time slots as well as the
ways we can manage the order amidst
the already running production. Even
if we are overbooked, the machine will
suggest to distribute it on multiple
lines even if it’s just a work of 2 lines.
I will lose efficiency here. Hence, we
need a business analyst who will
understand the business right from
the start to the end and will know how
to play with this data so that I do not
lose my productivity.”
It’s a fact that machine requires data
to be fed into it and this is where Delta
has improvised. “Now what we do is
either we prepone all bookings and
approvals or reshuffle all the lines
so that we don’t lose money on new
orders and on the other hand, we
also do not decrease productivity on
already running orders. This is what
an efficient business analyst can do
for us,” boasts Rupak.
However, improving productivity does
not just depend on data management.
Sensing the fact that managing a
factory is a very complex game, both
verticals (garment divisions) of the
Delta Group are extensively working
to lower the impact of critical elements
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