East West University

Graduate Diploma in Leather & Footwear Management

Internship Report
On
Production & Quality Management
A Study on

Submitted to:
Mr. Nazmul Hassan
Senior Lecturer
Department of Business Administration
East West University

Submitted by:
Basudev Biswas
Student ID: 2022-2-69-024
Batch-07; Section-02
Summer-2022

Date of Submission: 30th April 2023

1
 Certificate of Internal Supervisor

This is certify that the Internship Report entitled “Production & Quality Management; A Study
on A & A Shoes Ltd.” submitted by Basudev Biswas, Student ID: 2022-2-69-024 for the partial
fulfillment of the Graduate Diploma in Leather and Footwear Management (GDLFM) Program
offered by the Executive Development Center (EDC) of East West University during the semester
Summer-2022. This is an original work carried out by the student under my supervision.

I had this amazing opportunity to supervise Basudev Biswas who has so much potential in herself.
He has offered his utmost service to this internship and has completed successfully. I wish his all
the success in his future life.

Mr. Nazmul Hassan

Senior Lecturer
Department of Business Administration
East West University

2
 Certificate of External Supervisor

This is certify that the Internship Report entitled “Production & Quality Management; A Study
on A & A Shoes Ltd.” submitted by Basudev Biswas, Student ID: 2022-2-69-024 for the partial
fulfillment of the Graduate Diploma in Leather and Footwear Management (GDLFM) Program
offered by the Executive Development Center (EDC) of East West University during the semester
Summer-2022. This is an original work carried out by the student under my supervision.

I had this amazing opportunity to supervise Basudev Biswas who has so much potential in herself.
He has offered his utmost service to this internship and has completed successfully. I wish his all
the success in his future life.

Shahrear H Chowdhury
Executive Director
A & A Shoes Limited.

3
 Declaration

Basudev Biswas, declare that the Internship Report entitled “Production & Quality
Management; A Study on A & A Shoes Ltd.” of an original work done by me under the guidance
of Internal supervisor, Mr. Nazmul Hassan, (Senior Lecturer, Department of Business
Administration, East West University) and External supervisor, Shahrear H Chowdhury,
Executive Director, A & A Shoes Ltd.

I confirm that the project work I am submitting is an original and real piece of work written solely
by myself that maintains the proper rules and regulations with respect to plagiarism and collusions.
I further confirm that the taken materials and information are fully referenced and acknowledged.

Basudev Biswas
Student ID: 2022-2-69-024
Batch-07; Section-02
Summer-2022

4
 Letter of Transmittal
Date: 30th April 2023

Mr. Nazmul Hassan

Senior Lecturer
Department of Business Administration
East West University

Subject: Application for the submission of Internship report.

Dear Sir,
I am glad to submit my Internship Report on “Production & Quality Management; A Study on
A & A Shoes Ltd.” for my intern work of Graduate Diploma in Leather and Footwear
Management (GDLFM) Program. It is my privilege that I had the opportunity to prepare this
project under your supervision and guidance.

This project gives a detailed insight of how the footwear industry works. I have tried my best to
work on every detail even though I faced some obstacles. This project was a really valuable
experience for me which has broadened my horizon further in various ways.

For your kind consideration, I would like to mention that there might be some mistakes due to my
limitation of my knowledge and time constraint. In spite of various obstacles, I tried my best to
cover all the ground relevant to this project. I hope that my report will be able to meet up your
expectation and you will appreciate my endeavor and the report emphatic.

Basudev Biswas
Student ID: 2022-2-69-024
Batch-07; Section-02
Summer-2022

5
 Acknowledgement

First of all, I would like to show the gratitude to the “Almighty” who gives me the best opportunity
to complete this report successfully with good health and sound mind. All praises are for
“Almighty” who is always very kind to his subjects.

This Industrial Training would be impossible if I didn’t get cordial assistance of people and I would
like to take the opportunity to tanks all those persons who have encouraged and supported me
about this program.

My first acknowledgement especially to East West University for arranging such program. My
deepest gratitude to my Internal supervisor, Mr. Nazmul Hassan, (Senior Lecturer, Department
of Business Administration, East West University) for constructive suggestion on this internship
and I am very grateful for his guidance.

Special thanks to A & A Shoes Limited. For giving me the opportunity of Internship-Industrial
Attachment. I am grateful to all the personnel involve with this company and especially grateful
to my external supervisor, Shahrear H Chowdhury (Executive Director, A & A Shoes Ltd.) for
their cordial cooperation and proper guidance.

Finally, I thank my family and friends for their inspiration and cooperation.

6
 Abstract

This Report based on the Production & Quality opportunities in international market for
Bangladesh as Production & Quality Management a study on A & A Shoes Ltd. The study noted
that there is have huge export opportunities in international market from Bangladesh as well as
describing system Production & Quality Management of the company.

In the report, I have discussed about how leather & Footwear industry is going in tremendous way
with come up together upgrading technology with follow the system & procedure.

The Leather & footwear industry is a booming and one of the second largest manufacturing sectors
in Bangladesh. This study was carried out in a leading leather & footwear manufacturing industry
in Bangladesh for the Sport shoe production line. The main target of this study was to reduce the
lead time by maintain quality with follow the SOP/SYSTEM.

To sum-up, I would like to say that a lot of export opportunities are available around us. Now have
need to focus on producing high quality leather goods and footwear for export purpose.

7
 Table of Content

Sl No. Chapter Description Page No

Summery
1.1 Certificate of Internal Supervisor 2
1.2 Certificate of External Supervisor 3
1.3 Declaration 4
1.4 Letter of Transmittal 5
1.5 Acknowledgement 6
1.6 Abstract 7
1.7 Table of Content 8-9
Chapter- 02 (Introduction)
2.1 Introduction 11
2.2 Background of the study 11
2.3 Objective of the study 12
2.4 Scope of the study 12
2.5 Methodology 13
2.6 Limitation 13
Chapter -03 (Literature Review)
3 Literature Review 15-16
Chapter -04 (History of leather And Tannery industry in Bangladesh)
4 History of leather And Tannery industry in Bangladesh 18-19
Chapter -05 (Market Opportunities)
5.1 Footwear Market Global Opportunities 2022 21
5.2 Top growing factors by Key Companies like: 22
5.3 The scope of the global Footwear market: 23
5.4 Abstract 23
Chapter -06 (Intern Organization) A & A Shoes Ltd
6.1 Introduction: 25
6.2 History 25
6.3 Background 25
6.4 Vision : 25
6.5 Mission : 25
6.6 Objectives: 26
6.7 Quality Statement: 27
6.8 5 Core Values: 28
6.9 Listen; Think; Solve 29
6.10 Company Overview 30
6.11 Board of Directors 31
6.12 Floor Management Chart 32
6.13 Business Model 33
6.14 Production Flow Chart 34
6.15 Details of Production 35
6.16 Brand LOGO 36
6.17 Company Product/Service Offerings 37

8
6.18 Compliance Initiative Picture 38
6.19 Department Picture 39
Chapter -07 (Raw Materials Management)
7.1 Introduction: 41
7.2 Lamination 42
7.3 Cutting 43
7.4 Printing 44
7.5 Setting/Preparation 45
7.6 Outsole/Rubber Plant 46
7.7 Outsole/EVA Plant 47
7.8 Foam Plant 48
7.9 Stitching 49
7.10 Assembly 50
7.11 Quality 51-52
7.12 Quality Inspection 53-55
7.13 Planning Process of Implementation 56
7.14 Production Plan 57-58
7.15 Merchandising 59
7.16 Product Development/R & D 60-62
Chapter -08 (Raw Materials of Footwear)
8.1 List of Raw Materials 64-65
8.2 Parts of Raw Materials 65-66
Chapter -09 (Practical Experiences)
9 Practical Experiences 68
Chapter -10 (Recommendations & Conclusion)
10.1 Recommendations 70
10.2 Conclusion 71
10.3 References 72

9
Chapter -01
(Introduction)

10
Introduction
Leather Industry was developed in Bangladesh on a large-scale mainly in the 1970s as one of the
largest industries of Bangladesh. The government considers 'leather goods and footwear' as one of
the main growth generators for the country.

Bangladesh leather industry makes leather-based products such as garments, shoes, belts, bags,
and jackets, suitcases, wallets, and some accessories items. These products are sold both in the
domestic and foreign markets. Leather footwear is the fastest growing segment of the leather
industry. Bangladesh meets the demand for about 15% of the world’s total leather market.

According to the “Leather Goods and Footwear Manufacturers and Exporters Association of
Bangladesh (LFMEAB)’’ the domestic demand of leather footwear and goods was worth about Tk
160 billion but 40 percent of the demands are met by importing goods from abroad.
The leather & Footwear industry, country’s second largest export-earning industry, is
observing a continuous decline in export earnings. According to the data of Export Promotion
Bureau (EPB), export earnings from the leather and leather products declined by 16.11% to
US$434 million in the five months of the fiscal year 2022-2023, which was US$518 million in the
same period last year.
In fiscal 2021-2022, according to data from the EPB, export of leather, leather goods, and footwear
were USD 1.08 billion. In 2020-2021, Bangladesh exported leather and leather goods worth $1.23
billion, compared with $1.16 billion in the previous fiscal year. Export earnings from the leather
& leather products declined by 16.11% in the five months of the current fiscal year. Therefore, it
shows that the sector is not having a strong and remarkable growth.

Background of the study

Internship-Industrial Attachment (LF-901) is an important part of the Graduate Diploma in Leather

and Footwear Management (GDLFM) Program. It creates opportunities for trainees to acquire
professional and interpersonal skills and build relationship with industry management and
workers. In this program, they are assigned to make a report based on their industrial attachment
on a particular topic by his/her both internal and external supervisor. This report enables a trainee
to develop their analytical skills, demonstrate their ability to solve problems and acquire practical
knowledge about the environment of the organizations. At the end of the day, it reflects what they
learned throughout the program and finally they submit their reports in front of the supervisors.

11
Objective of the study

 The primary objective

The primary objective of preparing this report is to show the export opportunities in
international & local market as well as describing Production & Quality Management; A Study
on A & A Shoes Ltd.

 The secondary objective

 To show the current situation of export market.
 To show the current situation of local market.
 To describe the export opportunities in international market.
 To know about the industrial production system.
 To objective the management & planning system.
 To concern about the plan layout of the factory.
 To have a closer & effective look at each and every unit step of footwear manufacturing.
 To compare between institutional and industrial working techniques and procedures.
 To have a concept on production plan.

Scope of the study

This internship program gives me a great opportunity for gathering experience and knowledge in
several areas of footwear manufacturing process by which I can evaluate or expose my life. The
scope of study is huge to A & A Shoes Limited. Because all the employees are very helpful and
co-operative. As the report is based on practical observations, I was assigned at every department
of Production & Quality Management process as Footwear, Footwear Accessories (Sole), Leather
Goods with packaging and observe their production process and observe the work practically.

12
Methodology
All information related to the topic is collected from both primary and secondary sources.
Primary Source:
Primary data are collected from face-to-face conversation and physically observations all
department as Footwear, Footwear Accessories (Sole), Leather Goods with packaging at A & A
Shoes & Ltd. The sources of primary data are shown in below.

 Personal experience gained by the visiting different department.

 Face to face conversation with the external supervisor.
 Personal conversation with their employee.

Secondary Source

 Annual report of Leather-goods & Footwear Manufacturers and Exporters Association of

Bangladesh (LFMEAB).
 Lecture Sheets provided by the Teacher in Class room (EWU).
 Materials provided by the external supervisor.
 Different journal, newspapers and website.

Limitation
I have tried my level best to provide with all necessary information but due to exhaustive nature
of this study most secret & strategic information could not be shown in this report. As having the
status of the somewhat empirical study, this report is subject to following limitation.

 Unavailable information: To prepare the project I have faced so many problems because some
specific information was not available in online regarding export opportunities of leather industry
and that is why I have little information.
 Limitation of related with the company: The employees of this company were too busy of their
work. For this reason, they did not get sufficient time to fulfill my queries and share something in
details.
 Accuracy: There was some irrelevance information in the different websites and journal with
compare to previous your information but I have tried to cop up the situation accurately in this
project.
 Information gathering: It was quite difficult for me to collect information from website since it’s
not enriched with information. Though I got maximum information from my level best hard work.
 Hidden Information: Most of the employees are not interested to disclose their strategic planning
related information because of their personal limitations.

There are some related documents and journals are written in English and written by professionals.
So, many of the key words have been used there in their own language which gave me pretty hard
time in analyzing them.

13
Chapter -02
(Literature Review)

14
Literature Review
According to the Leather Goods & Footwear Manufacturers and Exporters Association of
Bangladesh (LFMEAB), the domestic demand of leather footwear and goods was worth about TK
160 billion but 40 prevent of the demands are met by importing goods from abroad.
The Footwear Industry in Bangladesh has started since the colonial era, although its modernization
took place only in the late 1980s. During the British period, there was no footwear manufacturing
firm producing on a mass scale in East Bengal. However, a traditional cottage type footwear
industry with limited production facilities existed in a skeleton form in the district towns during
that time. Various types of footwear were imported, mainly from Calcutta. After the partition of
Bengal in 1947, footwears were imported from West Pakistan.
When Bata Shoe Company established its manufacturing plant at Tongi in 1962, it was the first
manufacturing plant to produce shoes on a large scale in East Pakistan. In 1967, Eastern
Progressive Shoe Industries (EPSI) established its production plant. It began exporting footwear
to USSR, Czechoslovakia and England. Both Bata and EPSI held major shares in the local
footwear market. The footwear industry suffered a major setback during the war of liberation but
was rehabilitated after independence. New footwear manufacturing units have recently been
established. Among them are Apex Footwear Limited, Bay Emporium Limited, Express Leather
Products Limited (Lotto), Excelsior Shoes, A & A Shoes Limited, Paragon Leather and Footwear
Industries & many more...
Japan and Germany, Italy are now the biggest markets for Bangladeshi footwear but US buyers
are increasingly showing interest in sourcing from Bangladesh. Bangladesh could have a billion-
dollar footwear export sector by 2013, claim local shoe manufacturers on the basis of both the
current growth in shipments and the increased production capacity in factories under construction.
If their assessment is correct, in a three-year period the level of exports can increase five-fold from
the $205 million worth of shoes that were exported in the last fiscal year that ended in June 2010.
Bangladesh has a host of potential products that can earn substantially large amounts of foreign
exchange, if only the necessary patronage from the overseas buyers is given for the sake of
expanding the country’s export base and thereby reach a sustainable status for the country’s export
trade.
Recently, a new opportunity has opened up to further diversify the range of Bangladesh’s export
base by including footwear and other leather goods in the list of exports particularly to the
European Union (EU) market.
However, the country has already been exporting finished leather and different kinds of leather
products to the overseas markets. These products also enjoyed considerable demand because of
their high quality. The main reason for this was the natural advantage of leather that Bangladesh
produces. Despite the high quality of local animal hides both in raw and finished form, Bangladesh
was still trailing behind Vietnam and China in the export of footwear and other leather products in
the European and other markets.
Bangladesh is set to emerge as the next manufacturing hub for the global footwear industry. The
cheap labor is prompting top manufacturers to relocate their factories in the country. The good
news is that a number of foreign investors as well as buyers have already shown interest in
Bangladesh’s leather and footwear sector.
Recently, the president of the Bangladesh Finished Leather, Leather Goods and Footwear
Exporters Association (BFLLGFEA) informed all concerned that three large investors in the
15
footwear sector from Taiwan would set up footwear factories in the Dhaka and Chittagong
Exporting zones. The buyers from EU, as well as other very highly developed industrial nations
like Japan have reportedly been showing importance in Bangladeshi leather products. All these
developments look promising for the local footwear industry.
The Export Processing Zones at present have 20 shoe and leather goods factories but there are at
least 10 large factories under construction, mostly owned by big manufacturers in the shoe world.
The factories under construction include Korean company Young One’s footwear complex which
is said to be the largest in Asia. The company started construction of its mega shoe complex in
Chittagong six months back. The first part of the complex will go into production by the middle
of next year, and the company’s executives said they would be able to manufacture about 30
million pairs of shoes by 2013.
In addition, Taiwanese shoe manufacturer Pau Chen, which employs about 4,00,000 workers in its
factories in China and 50,000 in Vietnam, is also building a large manufacturing facility in
Chittagong. Australian manufacturer Bonshoe BD Ltd. , a supplier to Hugo Boss, and Xen Chen
and Genford of Taiwan., are also building footwear factories in Bangladesh. Apex-Adhelci also
has a new factory that will soon start production. With an annual turnover of about $100 million,
the Bangladesh-Italy joint venture is now the largest exporter of footwear. However, with a new
joint venture factory, Blue Ocean Footwear, due to go into production by February 2011, Apex
will get involved with a turnover of nearly $200 million of footwear export by 2013.
The local footwear industry is experiencing an annual growth rate of 21 percent, according to a
spokesman from another apex organization, Leather Goods and Footwear Manufacturers and
Exporters Association of Bangladesh (LGFMEAB). However, to continue the trend, the present
level of growth has not only to be attained; it also has to be taken to a still higher level, if
Bangladesh is to match the success of its immediate competitor, Vietnam.
According to a newly released statistics from the Export Promotion Bureau of Bangladesh,
footwear exports from the country grew from US$61 million in the period of July-November 2007
to $85 million in the same period of 2008, recording a growth of 39 percent. In the first four months
of the 2010 fiscal year there has been $98 million worth of exports, a 65 per cent increase from the
same period last year. Taking this rate of growth into account, shoe industry executives estimate
that the current fiscal year’s footwear export is likely to cross $300 million. Though in the next
two years the existing factories are likely to export more shoes, it is the new capacity that will
come on stream from early 2011 that is expected to cause the huge spurt in growth.
Growth in exports is due to the low production cost in Bangladesh compared to its neighboring
countries: China, India and Vietnam, who also have a very well entrenched leather and footwear
export industry. Orders which earlier used to be given to China or India are now being handed out
to footwear manufacturers in Bangladesh because they are able to produce low-priced but quality
shoes, which have now found its way in to key markets in EU and Japan.

16
 Chapter -03
(History of Leather and Tannery Industry in Bangladesh)

17
 History of leather And Tannery industry in Bangladesh

Leather processing is an old assembling sub-segment in Bangladesh with a long legacy of more
than six decades. Accessibility of indigenous raw material (hides up and skins) encouraged the
setting up of the business in the mid-1940s in the then east Bengal. During Pakistan period (1947-
1971), the industry was commanded by non-Bengali vagrants from India, who had the learning
and the know-how of leather preparing industry. Around then, leather processing was limited to
the production of wet blue leather (semi-processed tanned leather) and the non-Bengali dealers
exported a large part of the produce to West Pakistan for additionally preparing and generation of
leather merchandise. A couple of little tanning units were owned by Bengali businessman who
processed leather predominantly for the local market.
After the independence of Bangladesh, the administration assumed control over the tannery
industry relinquished by the withdrawing non-Bengali business entrepreneurs but had limited
success in working them in the public sector. Export of processed leather composed completely of
wet blue leather till 1980-81. After 1981, of policy support measures aimed for raising the level of
value addition in the industry provided the incentive for new private interest in the leather industry.
The prohibition on the export of wet blue leather in June 1990 prompted the setting up of modern
leather tanning units for the production of outside leather (tanned leather after further processing
of wet blue leather) and finish leather and this was followed by new investment in leather products
industry, especially leather footwear.
However, till 2004 the leather industry involves just a humble position in Bangladesh economy
was below its actual potential. Along these lines, in 2001-02, esteem expansion in leather
endeavors with at least 10 specialists added up to Tk. 8,737 million ($152 million), which was
around 3 percent of assembling esteem included that size gathering of businesses. Leather footwear
represented 28% of the fair profit from leather and leather items in 2007-08, while the offer of
leather and other leather items was 68% and 4% separately. Hence, despite its little size, leather
industry in Bangladesh appears to have experienced the huge change amid the previous two
decades from a low-esteem option tanning action to a maker of leather footwear and leather
merchandise alongside high esteem included outside layer and completed leather.
By 2011-2012, the contribution of the leather industry to the Bangladesh economy was more them
US$500 million, representing 3% to 4% of nation's export. Recent export trends demonstrate that
the footwear sector (value added stock), is becoming the fastest. The figure demonstrates that
performance with regard to footwear is increasing considerably. Additionally, progress in such
manner is required in the years to come. As of now, there are more than 30 automated footwear
organizations in the country, most produce leather footwear for the worldwide export. A large
number of semi-mechanized and, non-automated footwear units are also operating in the domestic
market. Somewhere near about 15 or 20 companies produce high- quality leather products which
are consistently exported in good demand. Export performance can be foreseen to increment in the
following five years with no less than 12-15% growth in turnover for each annulus. In the
following years, the current footwear factories are probably going to exports shoes. The new

18
capacity [expanded and new factories] that will go ahead stream from late 2017 will give increased
growth. The export processing Zones (all through Bangladesh) at present have the more than 20
shoe and leather products industrial facilities and there are at least several large factories under
construction.

19
Chapter -04
(Market Opportunities)

20
 Footwear Market Global Opportunities 2023
The global Footwear Market report prepared by the Research Industry US covers a complete set
of analyzed information about the global Footwear Market in a well-informed arrangement. The
report offers an extensive platform full of prospects to the specific organizations, associations,
manufacturers, industries, firms, and vendors that are constantly working on their business
expansion at a global level.
A well-described content associated with the key Footwear Market competitors is also given in the
market report. The report also provides brief information about still developing industries, which
are competing with the key industries in terms of manufacturing quality, revenue generation, after-
sales service, and demand & sales.
The research study also shows imminent market trends based on production technology, industrial
development plans along with advancement in technology held at Footwear industry. The research
study also offers an independent analysis of the basic’s concepts of the Footwear Market.

Following questions are answered in this report:

 What will be the market size in terms of value and volume in the next 8 years?
 Which segment is currently leading the market?
 In which region will the market find its maximum growth?
21
  Which players will take the lead in the market?
 What are the key drivers and restraints of the market growth?

Top growing factors by Key Companies like:

Puma
Nine West
Asics
Adidas
Wolverine Worldwide
Nike
Belle
Skechers
Clarks
New Balance
VF Corp
Kering Group
LIDL
Under Armour
UMBRO
Crocs Inc
ECCO
Daphne
Salvatore Farrago
LI-NING
And Others

The Footwear Market report provides company market size, share analysis in order to give a
broader overview of the key players in the market. Additionally, the report also includes key
strategic developments of the market including new product launch, mergers & acquisitions,
collaborations & joint ventures, agreements, partnerships, research & development, product and
regional expansion of key participants involved in the market on the global and regional basis.

22
The scope of the global Footwear market:
For the better perceptive of the market, this report has provided a detailed analysis of drivers,
restraints, and trends that control the present market scenario and also the future status of the global
Footwear market during the projected period of 2022-2030. The report has segmented this market
based on regions like North America, Europe, Asia-Pacific, South America, and the Middle East
& Africa.
While classifying these segments, the specialist team of analysts has listed the relative impact of
each segment for the growth of the global Footwear market. Significant information of segments
is obligatory to recognize the key trends persuading the global market for Footwear.
Each segment of the market offers a piece of in-depth information on the qualitative and
quantitative analysis of the market. While giving a concise idea about the revenue opportunities
for all the segments, this report has also presented the value of absolute dollar opportunity for all
the segments over the predicted period of 2022 to 2030.

Abstract

 The report covers the forecast and analysis for the Footwear Market on a global and
regional level. 
 The report includes the positive and negative factors that are influencing the growth of
the market.
 The revenue generated by the leading industry players has been analyzed in the report.
 The market numbers have been calculated using bottom-up and top-down approaches.
 The Footwear Market has been analyzed using Porter’s Five Forces Analysis. 
 The market is segmented based on types and applications/end-users, which in turn is
bifurcated on a regional level as well. 
 All the segments have been evaluated based on present and future trends.
 The report deals with in-depth quantitative and qualitative analyses of the Footwear
Market.
 The report includes detailed company profiles of the prominent market players.

23
Chapter -05
(Intern Organization)

A & A Shoes Ltd.

24
Introduction:
My internship attachment was with A & A Shoes Limited; a dynamic manufacturing organization
with wonderful work ethic and environment. In my 3 months attachment with this organization, I
have learnt a lot, thanks to the wonderful mentors who took their time to teach me everything about
modern day of Production & Quality Management. This section discusses the organization in brief,
its operations, its clients and its values.

History:
Some of the significant milestones of the company are as follows:

Background:
A & A Shoes Limited. Is one of the fastest growing footwear manufacturing in Bangladesh,
working with multinational brands In 2018, A & A Shoes Limited entered the country’s booming
shoe industry with lot of hope. Over the years, unwavering interest and determination have helped
royal earn a respectable position in the country’s footwear industry. Now a days the make Quality
Out sole EVA, CROCK, RUBBER, FOAM & SPORTS SHOE.

Vision:
Growth through stakeholders’ satisfaction.

Mission:
To satisfy our customers’ desire to look good by providing commercial fashion footwear, Leather
goods at superior value and quality, in a unique format served by competent sales associates.

25
 OBJECTIVE:

To achieve our mission through customer satisfaction, brand

enhancement, product differentiation and operations
excellence without compromising on quality and profitability.

26
 Quality Statement

We are committed to providing our customers with superior

quality products and services at competitive prices that
continually meet or exceed customer expectations

Environmental Mission

To protect our people, customers and communities and to

protect our natural environment in order to help sustain
human development globally.

27
 5 CORE VALUES:

People

I) People: Valuing and developing people

II) Integrity: Integrity in all dealings

III) Quality: Excellence in everything we do

IV) Innovation: Adapt to latest technology and take new initiatives

V) Customer: Total commitment to Customer Satisfaction.

28
Listen - voice of customers (VOC)

Think -

Long experience, industry

knowledge, access to international
markets, team.

Solve - Speed, package deal, and customer’s demand.

29
 Company Overview

A & A Shoes Ltd. holds the capacity to produce 6.00 MILLION pairs per year of
mainly sports shoes, casual shoes or sandals for men, women and children. The shoe
constructions are mostly cemented, sock lasting, string lasting and moccasin type
assembly. Machineries are imported from India, Italy, China and Taiwan.
Outsole produce capacity 2.4 MILLION for Rubber & Crock also. Its EVA process
by world’s class Main group & press mold type machine.

Clients:

The company has various international buyers who have continuously taken products
from A & A Shoes Ltd. Three sales channels, dedicated for export
operations, targeting the international market.

30
BOARD OF DIRECTORS

31
FLOOR MANAGEMENT CHART

32
33
PRODUCTION FLOW CHART

34
The shoe making process with outsole detailing typically involves several steps, which may vary depending
on the type of shoe being produced and the specific materials and techniques used. Here is a general overview
of the process:

 Design and pattern-making: The shoe designer creates a design for the shoe, which includes the shape
and style of the upper (the part of the shoe that covers the foot) and the outsole (the bottom of the shoe
that comes in contact with the ground). A pattern is then created based on the design.
 Cutting: The upper and lining materials are cut according to the pattern. The outsole is also cut to the
appropriate size and shape.
 Skiving: The edges of the upper and lining materials are thinned and smoothed to reduce bulk and
create a cleaner finish.
 Stitching: The upper and lining materials are sewn together, either by hand or by machine, to create
the basic structure of the shoe. The outsole may also be stitched to the upper at this stage.
 Outsole: The outsole making process is a crucial part of shoe manufacturing, as it determines the
quality and durability of the shoe. Here is an overview of the outsole making process with details:

 Material selection: Outsoles are typically made from rubber, leather, or synthetic materials. The
selection of the material depends on the desired properties of the outsole, such as slip-resistance,
flexibility, and durability.
 Molding: The first step in creating an outsole is to mold it into the desired shape. This can be done
through injection molding, compression molding, or other molding techniques. In injection molding,
molten rubber or other material is injected into a mold, which is then cooled to create the desired
shape. In compression molding, the material is placed in a mold and heated and compressed to create
the shape.
 Trimming: After the outsole is molded, it is trimmed to remove excess material and achieve the
desired size and shape.
 Roughing: The surface of the outsole is roughed up to create a better bonding surface for the adhesive
that will attach it to the shoe.
 Grooving: The outsole may be grooved to improve traction and flexibility. This is typically done
using specialized equipment that cuts grooves into the surface of the outsole.
 Finishing: The outsole is then finished with a variety of techniques, such as grinding, buffing, or
polishing, to create a smooth and even surface. Any additional details, such as logos or patterns, may
also be added at this stage.
 Quality control: The outsole is inspected to ensure that it meets the manufacturer's quality standards.
This may include tests for durability, slip-resistance, and flexibility.

Overall, the outsole making process requires specialized equipment and skilled craftsmen to produce
high-quality outsoles that will provide the necessary support and protection for the foot.

 Lasting: The shoe is placed on a last (a foot-shaped form) to give it its final shape. The upper is pulled
taut over the last and attached to the insole and outsole.
 Gluing: The outsole is attached to the shoe using a variety of methods, such as adhesive bonding or
stitching. The outsole may also be trimmed and shaped at this stage.

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  Finishing: The shoe is finished by trimming excess material, polishing, and adding any final details,
such as eyelets or buckles.
 Quality control: The shoe is inspected to ensure that it meets the manufacturer's quality standards.

Overall, the shoe making process with outsole detailing is a complex and precise process that requires skilled
craftsmen and attention to detail at every step.

Brand Logo

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Company Product/Service Offerings:

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Chapter -06
(Production & Quality Management)

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INTRODUCTION

Production management refers to the process of planning, organizing, and controlling the production
process of goods and services to ensure that they are produced efficiently, on time, and at a high
level of quality. Quality management, on the other hand, refers to the process of ensuring that the
products or services produced meet or exceed customer expectations in terms ofquality, reliability,
and performance.

Both production management and quality management are essential for businesses to succeed in
today's highly competitive marketplace. By efficiently managing the production process, businesses
can increase productivity, reduce costs, and improve customer satisfaction. Quality management
ensures that the products or services meet or exceed customer expectations, which is crucial for
building customer loyalty and maintaining a positive reputation in the market.

Effective production and quality management require a range of skills, including planning and
scheduling, resource allocation, process optimization, quality control, and continuous improvement.
Companies that prioritize these areas are more likely to succeed in the long run and stay ahead of
their competitors.

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Lamination Process Management & Documentation

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Cutting Process Management & Documentation

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Printing of Process

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Preparation/Setting

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Outsole/Rubber Process Development & Chemical Management

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Outsole/EVA Process Development & Chemical Management

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Foam Process Development & Chemical Management

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Stitching Process Layout & SOP

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Assembly Process Layout & SOP

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Quality

According to AQL, Quality inspection is the most common method used to attain the
standardization and conformance to quality. It involves regular checking, measuring and testing of
the following:

(i) Incoming materials and parts;

(ii) (ii) One or more processes; and
(iii) (iii) Finished goods.

(A) Objectives of Quality Inspection

The Quality Inspection has the following broad objectives:

i. Identification of the problem
ii. Prevention of the occurrence of problems
iii. Elimination of the problem

(B) Responsibilities of the Receiving and Store Units

The responsibilities of receiving and store units are:

 The receiving officers collect information regarding the established standards of the incoming
materials and parts for their use in production. This information helps to keep a check on incoming
raw materials and parts from the suppliers in terms of quality.

• The receiving officers inspect all the containers for external damage. After unpacking of the
containers, they ensure that the items supplied are in good condition.

C) Stages of Quality Inspection

 There are three stages of Quality Inspection:

 Inspection of incoming materials and parts
 Inspection of production process/processes; and
 Inspection of the finished goods.

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i) Inspection of incoming materials and parts:

It is also called receiving inspection. It is checking, measuring and testing of incoming materials
and parts that are supplied before they are taken to store or inventory. Incoming inspection can be
conducted either at supplier's end or at manufacturer's gate. If the incoming materials are bulky or
large in quantity and involve huge transportation cost, it is economical to inspect them at the place
of vendor or supplier.

ii) Inspection of production process/processes:

This work of inspection is done while the production process is in progress. Inspection at
production house is very important to maintain the quality of products. Inspection at this point is
very helpful in preventing wastage of resources like materials, parts, time and money. It prevents
defective goods and minimizes the wastage.

iii) Inspection of the finished goods:

This is the last stage when finished goods are inspected before delivery to the customers. At this
point, the poor-quality products are rejected or sent back for further improvement.

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Quality Inspection Process & Documentation

1. Check the bulk production test report

2. Check scanning report & packing list
3. Matching purchase order (PO) sheet with product & carton
4. Select cartons for inspection
5. Select products for inspection
6. Check trims & accessories
7. Check products appearance & measurement point
8. Check hurtful material
9. Keep defect-free & defective products in the right box
10. Make a report of the inspection
11. Make a decision for the inspected products

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Planning Process of Implementation
 Order Quantity against shoe last quantity analyzes.
 Production capacity analyzes.
 Production GANG charts.
 Master plans.
Material incoming date.
Material issue date for lamination.
> Daily in-out with stock report by lot.
Cutting & issue date.
> Daily received & balance cutting report by lot.
Component processing Skiving, Hot fusing, printings, Embossing, Embroidery, and
Heat transfer Hi frequency & issuing date.
> Daily balance processing issued & report by lot.
Component matching {SUB STORE} & issuing date.
> Daily matching issued balanced report by lot.
Preparations stitch & issuing date.
> Daily received & issue balanced report by lot.
Upper Stitching & issued date.
> Daily received & issue balanced report by lot.
Outsole preparation plan & Assembly matching plan issue date.
> Daily matching received & issue balance {SUB STORE} report by lot.
Assembly & finishing shoes.
> Daily input & output balance report by lot.
Packaging & Packing list plan against by PO#
> Daily packing balance report by PO#
Shipment inspection plan.
> Daily shipment inspection passed & balance report.
Shipment Date & issue.
> Daily shipment balance issue & balance quantity report by order.

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Production Plan

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Merchandising

Merchandising refers to the process of promoting and selling products to customers. Here are the
steps involved in merchandising:

1. Product Selection: This step involves identifying the products that will be sold in the
store. Merchandisers must choose products that are popular and will sell well to the target
market.
2. Pricing Strategy: Once the products have been selected, the merchandiser must decide
on the pricing strategy. This involves determining the retail price of the product,
considering factors such as production cost, competitor prices, and customer demand.
3. Product Placement: The next step is to determine where the products will be placed in
the store. The goal is to make the products easily accessible to customers, and to ensure
that they are displayed in an attractive and eye-catching manner.
4. Visual Merchandising: This step involves creating an appealing and visually appealing
display for the products. This includes designing the store layout, creating attractive
product displays, and using signage and other marketing materials to draw attention to the
products.
5. Inventory Management: Merchandisers must keep track of the inventory levels of each
product to ensure that there is always enough stock on hand. They must also determine
when to reorder products and how much to order.
6. Sales Analysis: Finally, merchandisers must analyze sales data to determine which
products are selling well and which ones are not. This information can be used to make
adjustments to the product selection, pricing, and marketing strategies.

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Product Development / R & D

Product development, also known as research and development (R&D), is the process of creating
new or improved products, services, or processes that meet the needs of customers and provide a
competitive advantage in the market. The goal of R&D is to develop new and innovative ideas
that can be translated into successful products and services.

The product development process typically involves several stages, including idea generation,
concept development, design and prototyping, testing and validation, and commercialization.
During the idea generation stage, new ideas are brainstormed, and potential opportunities for
product development are identified. In the concept development stage, the ideas are refined, and
the most promising concepts are selected for further development.

The design and prototyping stage involves creating a detailed design of the product or service
and developing a prototype to test its functionality and performance. In the testing and validation
stage, the product is tested to ensure that it meets the desired specifications and performs as
expected. Finally, in the commercialization stage, the product is launched into the market and
marketed to customers.

R&D is essential for companies that want to stay competitive in today's fast-paced business
environment. By continually developing new and innovative products and services, companies
can stay ahead of their competitors and meet the changing needs of customers. Successful R&D
requires a range of skills, including technical expertise, project management skills, creativity,
and a willingness to take risks. Companies that prioritize R&D are more likely to succeed in the
long run and stay ahead of their competitors.

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Chapter -07
(Raw Materials of Footwear)

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List of Raw Materials:
Rubber: Rubber is most commonly used in shoes to make soles. While not the only
material used to make outsoles, it is among the most popular in sports shoes, like running shoes
and tennis shoes.

Foam: Foam is the most common material used to provide support in the uppers of shoes
of all sorts, be they leather, textile, synthetic or even rubber. The different types of foam used for
this purpose are innumerable, though they’re all generally divided into two categories: open and
closed cell. All foam is made from plastic. In open cell foam, the material is permeable, allowing
water and air to pass through; in closed cell foam, these open cells are sealed, preventing the gasses
inside them from escaping.
Open cell foam, also known as KFF or KF foam, is made of polyurethane plastic and tends to be
softer than closed cell foam. Open cell foam can often be found in the collars and tongues of shoes.
There are many different types of open foam, the most open of which is reticulated foam,
frequently used to create ventilation features in shoes.
Closed cell foam is a denser material commonly used to make shoe midsoles. Types of closed cell
foam include polyurethane and polyethylene, EVA foam, Neoprene and Latex. Each type of closed
cell foam features its own properties, such as waterproofness or elasticity.
Knowing the various materials most prevalent in shoes helps immensely in choosing the right
shoes to match your needs at the time. Understanding the variations in type, considerations of
quality and maintenance, and the prospective benefits and drawbacks of each type will help ensure
that you wear every pair of shoes you buy with pride.

Textiles: Fabric is also quite commonly used for making shoes. Like leather, textiles
are available in a wide array of colors and varieties. With textiles, the possible variations
include different fibers, denier (or fabric weight), weaves and knits.

The most common textiles used for making shoes are:

 cotton
 polyester
 wool
 nylon
Textile shoes can also be found in rayon, lira and polypropylene. One key advantage of textile
shoes is their versatility in styles and designs. Each textile also has its own physical properties that
must consider when choosing whether or not to own or wear it, such as variations in breathability,
support and temperature control.

Leather: Leather is flexible yet durable, as sturdy as it is supple. It’s elastic, so it can be
stretched yet it resists tearing and abrasion. It’s a breathable material, and it insulates heat, helping
to regulate temperature. This all makes leather shoes conform to the feet of the wearer like no other
shoe material can. It’s no surprise, then, that leather is one of the most common materials that
shoemakers use, particularly in making men’s dress shoes.

64
While most shoe rubber over the years has been made from polyester, a more environmentally-
sound natural rubber is increasing in popularity as an alternative.
Drawbacks to leather shoes include:
 leather is expensive compared to other shoe materials
 leather is heavy
 leather can get very hot
 leather untreated can be vulnerable to water damage
Because leather comes from animal hide, leather shoes can also bear slight imperfections.

Synthetics: Synthetic materials go by many different names– PU leather or simply PU,

synthetic leather or simply synthetics– but they’re all the same in being man-made composites of
two layers: an external surface adhered to a backing layer composed of polyester fibers. All types
of synthetics used to make shoes are also the same in making for supportive yet affordable sports
shoes. Like their textile counterparts, synthetic materials also come in a variety of colors and
textures.

Factors in the composition of the two layers comprising synthetic materials, such as whether the
polyester used for the backing is woven or non-woven, or the method of adhesion used, whether a
wet or dry process, determine the quality and durability of the resulting synthetic. Lower quality
synthetics may not have a perfectly smooth surface, even possibly showing creases and wrinkles.
The advantage of shoes made from synthetics is that they tend to be comparatively quite
inexpensive for both the manufacturer and consumer as compared with other types of shoes.
Because the material is less durable than its leather and textile counterparts, however, synthetic
shoes tend to degrade faster and need replacing more often.

Parts of Raw Materials:

Bottom Material
In socks Leather
Insole EVA
Socks
Out sole
Chemicals Item
Cyclone Hexanal
Screen printing ink
Rubber Solution
Latex
Neoprene Adhesive
EVA Primer
PU Primer
PU Cement
PU Hardener
Edge color
Top shining coat cream
Polishing Wax
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Sundries Materials
Color Foam
Velcro
TP Counter
Toe Puff
Marking Pen
Clean Pen
Needle
Metallic Ring
Metallic Logo-Hush Puppies
Heat transfer sticker
Reinforcement tape
Foil Paper
Upper Thread-Nylon
Bobbin Thread-Nylon
Moccasin Thread-Waxy
Packing Material
Bamboo Stick
Tissue paper-Shape retainer
Tissue paper-Warping
Shoe Box
Carton
Gum tape
Upper Material
Upper leather
Upper lining
Inter lining cloth

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Chapter -08
(Practical Experience)

67
 Practical Experiences

The Internship opportunity I had with A & A Shoes Ltd. was a great chance for learning
and professional development. Therefore, I consider myself as a very lucky individual as I was
provided with an opportunity to be a part of it. I am also grateful for having a chance to meet so
many wonderful people and professionals who led me thought this internship period.

I have learned about the Production Planning procedures – how to make a plan, how to coordinate
with all the parties to engage every party of the plan to make success. I also learned that how run
a business smoothly by facing all challenges. This program helped me to know how to take out
maximum output from the workers. It also taught me how to take the challenge and be the winner
by group work. After all, I have experienced such a working environment where everyone is
dedicated to achieve the organizational goals. Company provides excellent working environment
to the workers. They provide training to their workers to increase the efficiency of the workers.
After all, company works for the development and welfare of the workers and employees; workers
and employees also loyal to the company.

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Chapter -09
(Recommendations & Conclusion)

69
 Recommendations
A & A Shoes Ltd. is good in their quality management because their Quality Assurance (QC)
department is always busy to maintain standard qualityof their product. We all know ensuring good
quality of footwear is the most beneficial fact for a footwear market.
Some recommendations are to be specified here:

 The production unit should provide the workers with Personal protective equipment or
clothing and monitor whether they are using PPE or not.
 More regular training program (Non-Technical and Technical) on transactional
analysis, motivation, quality concept, productivity etc. should be organized on regular
basis.
 Employees should be more involved in decision making to become more differentiated.

 Effective steps should be taken to reduce the mistakes and improve the productivity and
quality.
 The work premises should be protected from outside heat and cold. Good welfare
facilities are an essential part of any enterprise producing leather goods. They improve the
worker’s attendance, job satisfaction, motivation, morale and health. It can be low- cost
investments.
 Company should have a budget for the Internee (Training and Development) for the
materials so that they can gain practical knowledge about the operations. 

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 Conclusion

Any kind of training in student life is very essential and fruitful. Student can get practical
knowledge from training. Theoretical knowledge only can be completed if one can apply it in
working field. Otherwise, the theoretical education will be useless. For that reason, such training
is a timely program. In the manufacturing field it is essential. Before completing engineering
course through training, we can also study the facts and lack of knowledge which we have faced
in training program. From this training program I have learnt many new operations, technical
works, terms, quality of products, quality control, quality assurance etc. which will help quick
adaptation in working field after completing engineering education. Designer have to be more
practical about production during product develop.

Finally, I want to conclude that while going through the entire industrial training period
from 22th January to 16th March, 2023 the cooperation is found to be very well organized,
developed & most ideal industry in every walk of its production, administration & management
aspects

I extend my heartiest thanks to A & A Shoes Ltd. for making the days to cherish for some of the
lucky students who are honored with their humble gesture to get an opportunity to be trained in
such an esteemed organization.

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 References

 www.a&ashoesbd.com
 http://www.apexfootwearltd.com/
 Com/wp-content/uploads/2016/09/Leather-Industry-in-Bangladesh.
 the Leather and Leather Products Industry Panel of the United
 info@grouperoyer.com
 info@lfmeab.org
 info@coelbd.com
 Prospects_of_Bangladesh_leather_industry.pdf.
 http://lfmeab.org/images/report/LEATHER_SECTOR_
 Malaysia Insights. 2014. Malaysia’s Shoe Industry Steps Up. 28August.

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