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TOT Program for Advanced Course in Garment Washing and Dyeing
TOT Program for Advanced Course in Garment Washing and Dyeing

TOT Program for Advanced Course in Garment Washing and Dyeing

TOT Program for Advanced Course

Introduction:

RMG industry is the most vital sectors in national economy of Bangladesh. Major foreign currency earnings come from this sector & it is mentionable that approximately 2 million workers are working in this sector of which almost 80% workers are female and 20% are male. A number of backward linkage sectors, Bank, Insurance and others business related industries established in Bangladesh. But this sector is now being confronted with a challenging situation due to open market; withdraw of quota system, Generalized System of Preference (GSP) and MFA-phase out, etc. Since, 2005 the Quota free system started in the RMG industry and at the same time international buyers are pressurizing on the issue of Quality and Compliance.

The South Asia Enterprise Development Facility of the International Finance Corporation (IFC-SEDF) is a multi-donor funded facility to support the establishment and growth of private small and medium enterprises (SMEs) in Bangladesh, Bhutan, Nepal, Northeast India, Sri-Lanka & Maldives. IFC-SEDF is managed by the International Finance Corporation, the private sector arm of the World Bank Group. IFC-SEDF started its operations in October 2002 and since then has completed numerous projects aimed at SME development.

One of the key focus areas of the IFC-SEDF is to build capacity of the service providers (SP) operating in the RMG sector. IFC-SEDF’s RMG component has been facilitating the SP’s in becoming more commercially viable by strengthening their ability to provide quality services. IFC-SEDF’s RMG component has recently started assisting and facilitating the washing, dyeing & finishing sub-sectors (critical nodes of the RMG supply chain) in becoming more commercially viable by strengthening their ability to provide quality services. One of the strategic areas of IFC SEDF is intervening in its improvement of product development skills of the RMG supply chain aimed at ensuring long term sustainability of the targeted SMEs.

With a view to building the capacity of potential local training service provider, IFC-SEDF has initiated to conduct a Training of the Trainers (TOT) on world class Garment Wet and Dry processing-finishing techniques. To increase the training service providers’ market outreach, IFC-SEDF is assisting the service provider to provide quality, sustainable services to the garment washing-dyeing-finishing industry of the RMG sector. The project involves training the organization’s current resource people and designing a course module for them to address productivity related issues.

With that end in view, IFC-SEDF now invites short-listed firms/institutions to submit their proposal in providing their services for conducting a Training of the Trainers (ToT) on world class garment wet & dry processing–finishing techniques to the resource personnel from the different training service providers.

Scope of work

An indicative, but not exhaustive list of Scope of Work is as follows:

  1. Need assessment with the participating group and design TOT accordingly in consultation with the training service provider(s).
  2. Theoretical and Practical knowledge sharing on total process of productivity, especially on the following topics :
(i) Introduction to and Theory of Garment Washing and Finishing       Introduction to Garment Washing and Finishing-Why washing is needed?      Fibres and Fabrics Subjected To Washing      Basic steps in Garment Washing & expected results      Machines and Equipment for Garment Washing and Finishing      Soil & Stain Removal theory behind and operation      Auxiliary Chemicals Used in Garment Washing and Finishing and their function, limitation
(ii) Washing and Finishing Effects of Garments by Physical Methods       Stone Wash, Sand Wash      Grinding      Brushing      Sanding      Sand Blasting      Laser burning/drawing      Tagging
(iii) Washing Effects of garments by Chemical Methods       Soft Wash      Enzyme Wash (Amylases, Cellulases, Catalases, Laccase etc)      Bleach Wash, Acid Wash      Peach Finish      Rinse Wash      Caustic Wash      Pigment Wash
(iv) Garment washing involving Physico-Chemical Methods       Bio Polishing      Permanent press & Wrinkle free finish      Scrunch Finish             Moon Wash      Rodeo Finish      H.D.W.      Ice wash, Snow Wash and Diamond Wash      Monkey Wash
(v) Garment Coloration Methods- Dyeing       Dyeing with Direct, Reactive and Pigments      Dip Dyeing      Tie and Dye                 Spraying      Air Brush printing      Discharging
(vi) Other garment finishes in demand       Softening      Water and Soil Repellent finish      Fire retardant finish
(vii) Quality Issues of Garment Washing and Finishing 1.      Handling defects in garment wash process: Creasing, Back staining, yellowing, Patchiness, Shade Variations, Holes and Damages, Roughness or poor softness – why and how to avoid2.      Physical & Chemical Degradation effects of Garment Washing–why and how to avoid3.      Quality of water and its impact on garment washing4.      Environmental Issues and Cleaner Production
  1. Train on training techniques.
  2. Take a pre-test at the outset of the training and a post-test at the end of the program and provide certificate to the successful candidates.
  3. Support in preparing a comprehensive course modules for the service recipients.
  4. The TOT program should preferably be of duration between 10 to 20 days.
  5. Upon participation of the TOT program the trainees should be able to achieve the following:
    • Understand the basic principles of garment washing and finishing.
    • Apply dry and wet processes to garments finishing.
    • Reduce waste in the process.
    • Develop the existing process for better quality and productivity.
    • To disseminate the knowledge and skills to the employees who have been engaged in the garment washing and finishing industry to improve the quality and productivity of the industry.
    • The participants will be able to demonstrate the garment washing and dyeing techniques to others who will learn from them.
    • Participants will be able to handle technical issues which arise due to the finishing process.
    • Will be able to understand properly buyers’ requirements in processing finished garments.

Project Description:

Background:

Garment Washing: Since 1978, garment pre-washing has become more and more popular. It began with denim jeans for the following reasons.

  • Before garment pre-washing was done on jeans, consumer had to wash them at home before wearing them because before washing they were too stiff, too long and too big to wear.
  • After pre-washing, the consumers do not have to worry about the fit after they wash them as pre-washing has taken away almost all the shrinkage and made the jeans stable.
  • After pre-washing the denim color looks more lively particularly with the pronounced washed look left on the double needled jeans.

In view of the above merit, garment pre-washing once started received great acceptance in the market. Not only it became popular, it flourished into many fashions to achieve different results. It is important to lean about different washing system in order to better control the quality and avoid problems which may emerge when the garment is washed.

Objective (purpose, types of objectives, need for specificity)

The objectives are:

  • Conduct need assessment on the participating groups and design a ToR as per requirement in collaboration with the training service provider.
  • Design training module on the following tropics for sharing theoretical and practical knowledge among the participants:
    • Introduction to and theory of garment washing and finishing
    • Washing and finishing effects of garments by physical methods
    • Washing effects of garments by chemical methods
    • Garment washing involving physical-chemical methods
    • Garment coloration methods – dyeing
    • Other garment finishes in demand
    • Quality issues of garment washing and finishing
  • Training on training techniques
  • Conduct pretest at the outset of the training and post test at the end of the program and provide certificate to the successful candidates
  • Support in preparing a comprehensive course module for the service recipient
  • Upon participation, the participant should be able to achieve the full concept of garment washing and dyeing

 

Who can attend in the ToT program:

 

Methodology

The approach and methodologies are drawn as per scope work

 

  1. Need Assessment with the participating group and design ToT accordingly in consultation with the training service provider(s).

Approach: The need assessment will be carried out through participatory exercise among the participants and design a ToT program as per the need of the participants in consultation with the Training Services Provider.

Methodology: A self assessment questionnaire will be used to judge the knowledge and experiences of the participants so that ToT training program can be designed to suite the requirement of the participants. The participants will be grouped by topics and in each group there would be a team leader. The team leader and the training consultant together will together decide the level of training to be introduced.

So that we can determine who can attend or who cann’t.

  1. Theoretical and Practical knowledge sharing on total process of productivity, especially on the topics wise :

 

Topic (i): Introduction to and Theory of Garment Washing and FinishingApproach: Lecture, Visit, Practice, discussion (Please select as appropriate)Methodology: Design Training Module taking into consideration the following:      Prepare the ToT Course Title: Introduction to and Theory of Garment Washing and Finishing      Duration  and Time to be required      Place      Lecture (person in charge)      Thematic Area      Objectives (Aims of the Lecture/Visit/…)      Outlines: 1.      Introduction to Garment Washing and Finishing-Why washing is needed?2.      Fibres and Fabrics Subjected To Washing3.      Basic steps in Garment Washing and expected results        4.      Machines and Equipment for Garment Washing and Finishing5.      Soil and Stain Removal theory behind and operation6.      Auxiliary Chemicals Used in Garment Washing and Finishing and their function, limitation

 

Topic (ii): Washing and Finishing Effects of Garments by Physical MethodsApproach: Lecture, Visit, Practice, discussion (Please select as appropriate)Methodology: The training module by topic will prepared in consideration of the following:      Prepare the ToT Course Title: Washing and Finishing Effects of Garments by Physical Methods      Duration  and Time to be required      Place      Lecture (person in charge)      Thematic Area      Objectives (Aims of the Lecture/Visit/…)      Outlines: 1.      Stone Wash, Sand Wash2.      Grinding3.      Brushing4.      Sanding5.      Sand Blasting6.      Laser burning/drawing7.      Tagging

 

Topic (iii): Washing Effects of garments by Chemical MethodsApproach: Lecture, Visit, Practice, discussion (Please select as appropriate)Methodology: The training module by topic will prepared in consideration of the following:      Prepare the ToT Course Title:      Duration  and Time to be required      Place      Lecture (person in charge)      Thematic Area      Objectives (Aims of the Lecture/Visit/…)      Outlines: 1.      Soft Wash2.      Enzyme Wash (Amylases, Cellulases, Catalases, Laccase etc)3.      Bleach Wash, Acid Wash4.      Peach Finish5.      Rinse Wash6.      Caustic Wash7.      Pigment Wash

 

Topic (iv): Garment washing involving Physico-Chemical MethodsApproach: Lecture, Visit, Practice, discussion (Please select as appropriate)Methodology: The training module by topic will prepared in consideration of the following:      Prepare the ToT Course Title:      Duration  and Time to be required      Place      Lecture (person in charge)      Thematic Area      Objectives (Aims of the Lecture/Visit/…)      Outlines : [ describe how this will be accomplished]1.      Bio Polishing2.      Permanent press & Wrinkle free finish3.      Scrunch Finish       4.      Moon Wash5.      Rodeo Finish6.      H.D.W.7.      Ice wash, Snow Wash and Diamond Wash8.      Monkey Wash

 

Topic (v): Garment Coloration Methods- DyeingApproach: Lecture, Visit, Practice, discussion (Please select as appropriate)Methodology: The training module by topic will prepared in consideration of the following:      Prepare the ToT Course Title:      Duration  and Time to be required      Place      Lecture (person in charge)      Thematic Area      Objectives (Aims of the Lecture/Visit/…)      Outlines: 1.      Dyeing with Direct, Reactive and Pigments2.      Dip Dyeing3.      Tie and Dye           4.      Spraying5.      Air Brush printing6.      Discharging

 

Topic (vi): Other garment finishes in demandApproach: Lecture, Visit, Practice, discussion (Please select as appropriate)Methodology: The training module by topic will prepared in consideration of the following:      Prepare the ToT Course Title:      Duration  and Time to be required      Place      Lecture (person in charge)      Thematic Area      Objectives (Aims of the Lecture/Visit/…)      Outlines: 1.      Softening2.      Water and Soil Repellent finish3.      Fire retardant finish

 

Topic (vii): Quality Issues of Garment Washing and FinishingApproach: Lecture, Visit, Practice, discussion (Please select as appropriate)Methodology: The training module by topic (vii) will prepared in consideration of the following:      Prepare the ToT Course Title:      Duration  and Time to be required      Place      Lecture (person in charge)      Thematic Area      Objectives (Aims of the Lecture/Visit/…)      Outlines: 1.      Handling defects in garment wash process: Creasing, Back staining, yellowing, Patchiness, Shade Variations, Holes and Damages, Roughness or poor softness – why and how to avoid2.      Physical and Chemical Degradation effects of Garment Washing – why and how to avoid3.      Quality of water and its impact on garment washing4.      Environmental Issues and Cleaner Production

 

Train on training Techniques:

 

Approach-1: How to prepare and conduct a participatory interactive sessionApproach-2: How to lead  a discussion : case study as a toolApproach-3: Experimental learning and how to run group exerciseMethodology:  ????

 

  1. Upon participation for the TOT program the trainees should be able to achieve the following:

 

What is to be achieved How to be measured
      Understand the basic principles of garment washing and finishing ·
      Apply dry and wet processes to garments finishing ·
      Reduce waste in the process ·
      Development the existing process for better quality and productivity ·
      To disseminate the knowledge and skills to the employees who have been engaged in the garment washing and finishing industry to provide the quality and productivity of the industry ·
      The participants will be able to demonstrate the garment washing and dyeing techniques to other who will learn from them      Participants will be able to handle technical issues which arise due to the finishing process ·
      Will be able to understand properly buyers’ requirements in processing finished garments ·

 

Deliverables for this project include a project proposal detailing:

 

Deliverables Describes the status
Technical Proposal detailing shape, size, schedule for the implementation for the ToT program
A Financial Propoal for turn-key solution for the said ToT program
The technical proposal must clearly state in detail :
What is not included in the proposal i.e. in case of any consultant requiring specific support resources from the client such as technical training venue, logistics, technology and equipment, raw materials and consumables, etc.

 

Specific experience of the consultant related to the assignment

Specific Experience of the Firm: Bangladesh Centre for Advanced Studies in collaboration with Stockholm Environment Institute, Sweden implemented a project title “Managing Industrial Pollution from Small and Medium – Scale Industries in Bangladesh”. The project was funded by DFID, UK, under its knowledge and research programme, the European Commission and the Government of Bangladesh. The project produced a good number of publications and these are very much useful for textile and dyeing sub-sectors. Some of the activities related to Garment dry and wet processing – finishing techniques are highlighted below as relevant industry experience of the firm:

Alternative Production and Cost Saving in Winch-Dyeing This booklet contains technical information on process of Winch Dyeing in dyeing industries.
Choosing Appropriate Reactive Dyes for Optimal Dyeing of Cotton This booklet contains information on Reactive dyes and their classification, compatibility of dyes, information on buying appropriate dyes etc.
Human Health and Industrial Pollution in Bangladesh This booklet contains information on pollusion caused by Textile and Dyeing  industries and its impact on human health.
Health and Safety in the Textile Dyeing Industry This is a published booklet. This booklet outlines some of the potential hazards of the various dyes and chemicals used in textile processing, and ways to minimize exposure to them. It provides some basic prevention measures that can be taken in the laboratory and on the factory floor to minimize risks of accidents and to ensure a safer working environment in the textile dyeing industry.This also include: Chemical Safety, Safety protocols, Responsibility of management and factory staff in maintaining the health and safety in the textile dyeing industry.
Management of Textile Dyeing Sludge This briefing note contains introduction on sludge and the method of safe disposing.
Testing the Compatibility of Reactive Dyes This booklet contains information related to :      How the dying factory can find out the compatibility of all dyes;      When selecting compatible dyes the dye manager should consider the full cost of the dyeing process and not only the cost of the dyes.      While checking the compatibility of dyes less salt should be used other wise initial uptake of the dye will be higher than usual.      Measurement of extinction coefficient for a single dye      Measurement of concentration and exhaustion of different dyes
Azo Dyes Briefing Note There are about 3000 Azo Dyes in use worldwide and they account for 65% of the commercial dyes. Currently only 22 aromatic amines are considered to be harmful and are banned in textile coloration under the EU Directive 2002/61/EC.This booklet contains information  in brief on Azo Dyes,  harmfulness of Azo dyes, list of Azo dyes, etc. which are very much helpful for enhancing the knowledge of the textile dyeing  technologist.

 

BCAS has a good working experiences with IFC-SEDF in other areas and following is a summary of such activities:

Cooperation Agreement between BCAS and IFC: Narrative Description of Project:

Under this cooperation agreement, BCAS will render its services as specified below:

IFC’s Responsibilities: IFC will provide promotional support for a specified number of training sessions conducted in the first 6 months from the date of signing of agreement :

  • Training Module –A : ETP Solutions and Cost Saving
  • Training Module –B : Health Safety and Environment
  • Training Module –C: Environment Impact Assessment
  • Training Module –D: Improving Environmental Efficiency and Cost saving of Industries

IFC will liaison with the RMG supply chain to ensure their participation.

BCAS’s Responsibilities:

  • Arrange venue and all logistical support for the training sessions
  • Communicate with the ETP buyers, association and relevant factory owners and ensure their participation
  • Ensure media and press coverage, with input from IFC
  • Provide monitoring data to IFC related to the training program

Memorandum of Understanding between BCAS and IFC

The purpose of this Memorandum is to set out the possible steps which could lead to the negotiation and execution of one or more cooperation agreement(s) between the Client and IFC in respect of the Project.

Under the scope of the MoU-BCAS will support sustainable Environment Management Systems for the RMG supply Chain in Bangladesh.

Performance Monitoring of the 11 RMG factories in terms of compliance of the Buyer:

This Agreement was signed between BCA, KarstadtQuelle (KQ) and 3p Institute for Sustainable Management (3p). Under this Agreement BCAS was responsible to monitor the following eleven suppliers of KarstadtQuelle in Bangladesh for another year based on the already successful qualification realized during the PPP-Project: Best Wool, Piakash, ABC, ABS, Claxton, Ansear, La Belle, Jeacon, Sababa, Tuba, Time Sweaters

BCAS is responsible to monitor the following activities:

To monitor if  there are adequate  person(s) appointed to take care of the following issues in the  company: freedom of association and collective bargaining, equal treatment / no discrimination, disciplinary practice, remuneration, working hours, health and safety, risk management, job security, child labour, voluntary employment, environmental protection, legal compliance, and security on premises

To monitor  the  comprehensive company rule pertaining to the following: freedom of association and collective bargaining, equal treatment / no discrimination, no disciplinary practice, remuneration, working hours, health and safety, risk management, job security, child labour, voluntary employment, environmental protection, legal compliance, and security.

To monitor that the appropriate procedures have been developed to ensure that the following issues are practiced and maintained in the company: freedom of association and collective, bargaining, equal treatment / no discrimination, no disciplinary practice, remuneration, working hours, health and safety, risk management, job security, child labour, voluntary employment, environmental protection, legal compliance and security

Standards for Sustainable Trade-IISD/Ring:

This project was implemented with financial assistance received from IISD-Ring, Islamabad, Pakistan. The activities performed under the scope of the project activities were:

  • Organizing regional workshop in Dhaka, participated by Government Organizations, Private Sector Business Bodies, Academic and Research Institutes and Civil Society/NGO
  • Identification of relevant stakeholders from Government, NGOs, Private Sector, Research Institutions and Civil societies.
  • Contact and inform them about the objectives and goals of the project.
  • Consultation with identified stakeholders and collection of information on the issue standard for sustainable Trade
  • Ascertain their willingness and interest in participating in the project.
  • Assess the general awareness of the various stakeholders about the constraints and technical barriers in export trade.
  • Assess their technical, institutional and human capacity to meet the requirements of TBT & SPS agreements and emerging national and voluntary standards for trade.
  • Compilation, review, analyses of collected data and computing
  • Report preparation on the study findings and dissemination to concerned agency/community.

 

Capacity Building and Developing Clean Development Mechanism (CDM) Project for Grameen Shakti (GS), Rahim Afrooz, and Energy Pac under SouthSouthNorth Project

The project was funded by the SouthSouthNorth Trust and it was a multi-county project. Countries involved were Bangladesh, South Africa, Brazil and Indonesia.

The objective of the project was to build capacity of government and business groups through developing and transacting CDM projects

The scope of activities were:

  • Prepare Country Scoping Report
  • Prepared Three CDM project
  • Help in setting up National Designated Authority (DNA)
  • Carryout Capacity Building Training
  • Help in validating CDM projects
  • Help in transacting CDM Projects

BCAS has an established Agreement with the College of Textile Engineering and Technology on “Managing Pollution from Small and Medium Scale Industries in Bangladesh”.

BCAS has been recognized as a partner to restore the degraded aquatic habitats within the joint MoU signed between Department of Environment (DOE) and Upazila Fisheries Committee (UFC), Kaliakoir on July 15, 2007

BCAS has an ongoing project with GTZ to Evaluate the Training Performance facilitated by the Pearl Fashion Institute to the participants participates from the member institutions of BKMEA.

Organized joint seminar with BGMEA and BTMA on “ETP and Cleaner Technology Option” during the month of September 17, 2005 and we have constant contact with these agencies to promote the issue further.

About Engr. Kh. Mashiur Rahman

He is Garment Automation Technologist and Editor in Chief of Autogarment. He is certified Echotech Garment CAD Professional-China, Aptech-India, NCC-UK and B.Sc. in CIS- London Metropolitan University, M.Sc. in ICT-UITS. He is working as a Successful Digital Marketer and Search Engine Specialist in RMG sector during 2005 to till now. Contact him- apparelsoftware@gmail.com

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