The Way of Smart Merchandising

The Way of Smart Merchandising
Muhammad Nurul Alam
Senior Merchandiser | Asmara BD Pvt. Ltd. | Dhaka | Bangladesh
Cell: +8801930540035
E-mail :

Do you know what is the working hour for a merchandiser in Bangladesh . Believe or not Merchandisers in Bangladesh are working more than 13-14 hours as regular job & some time much more . Always they are busy with hundreds of work schedule but nothing can be completed within office hour . So they have to stay in work place up-to late night . You can’t say this is only inefficiency of their profession because most of the time they are over loaded . The owners are having a cost minimizing tendency so they hire a Merchandiser instead of two or more without considering the demand of work load . As a result a merchandiser always fail to enjoy their regular life & gets tired . They loss their innovative force & feel exhausted in older years . We often see merchandiser who aged beyond 45-50 either loss their job or stay in the organization as a good for nothing . Owners don’t want to pay higher salary for him though they already have taken valuable energy ,time & work force in early age . This is really shocking that now they feel you are not to be used . Yes , right now we have to think how can take the best from our life period . Whatever the age we should have to keep energy & not to be exhausted . We can think for us from today & prepare a new deal for your career . To make easy & to be smarter merchandiser in our way of working please let us do something different . Today we are going to discuss how you can manage your thousands of job in a limited period of hours & can keep maximum energy .
Merchandiser work in office
Merchandiser work in office
1) Make a list of all your job:
This is very important what you are doing to keep it in your daily schedule . It would be better to make schedule 1st daily than weekly & finally monthly . Why this is important to do list ? First of all we are human being. So this is not possible to keep everything in our mind & to do the thing in priority basis . Usually a Merchandiser has to work through lots of stress as well as difficulties . For which this is not surprising if you see he is forgetting to do some most important task that should have to perform in first priority . The second thing is – when we see thousands of task that we have to perform within a very short period of time our nerves gets week . we feel exhausted & fatigue . So by the making schedule we can easily prioritize your task & get the most important & urgent thing .

The below diagram will help everyone to do list in the work priority . This may take little time to make your habit with the method but believe me the method is really effective .

Not Urgent
  1. Fabric booking
  2. Yarn procurement
  3. Price for new query
  4. PP sample submission
  1. Recape meeting with senior
  2. Production up-date
  3. Bulk Lot shade approval
  4. Factory visit & get the production status
Not Important
  1. File & Sample organizing
  2. System Up-date
  3. Price review
  1. New product collection
  2. Develop product knowledge
  3. Knowing up-date product status of other customer
2) Don’t put task for tomorrow:
Just keep in mind that tomorrow never come . If you are thinking today is for relax & tomorrow will be your busy day that would be unrealistic . Actually it does not happen because tomorrow you will see new task has added to do & in this way task will be more . One day without doing your important task means you are going to burden yourself for tomorrow .So whatever you think that should have be done today from your task priority list , do it immediately . Never wait for tomorrow.

3) Check double/Triple which is mathematical:
Usually a merchandiser works in a rush movement so sometimes it is not possible to do all the mathematical task in cool mind . Suppose you are going to book fabric or yarn . Here you have to calculate some figure to get the fabric amount that can be used for bulk . but for the all rush movement you made little mistake & proceeded for procurement . Your delivery time may be very short so without any revision of your booking hand over it to supplier & finally when the fabric in-housed it was identified what mistake you have done earlier during fabric booking. May be you mistake in color name or fabrication is wrong . Instead of 90/10 cotton/elastane you received fabric in 100% cotton . This is due to you worked in an old work order sheet where fabric was booked in 100% cotton & in the new sheet fabrication was not changed . The mistake is very little but outcome is devastating . To save time you did not give a cross check on the sheet & now all of your production schedule has gone to drain . This is really measurable when you will see your fabric is in-housed but cannot meet delivery date . Now again book the fabric newly & shipped the goods by air due to you missed delivery date . Actually this would not happen if you are careful & taking extra time give revision twice or triple . If you can take help from your colleague to see the booking as second party . This will help you to avoid extra hassle & to utilize your time properly . Here you can keep some key for cross check . cross check means the figure that should be off course changed in new booking . For fabric booking check the below
  • Fabric composition .
  • Fabric construction .
  • Fabric color .
  • Fabric width .
  • Finally Fabric Qty .
4) Don’t miss any mail:
A single mail can change total output . If you are not properly look into your mail & work through of it you may miss some important information . So read your every single mail & share the mail with all the relevant party . Don’t keep it in your box only . If you have some mail that you should give answer please keep it in red mark so that it will not go out of your track .

5) Don’t do a task twice:
This is actually relevant to point no 3 . Take extra time to do anything but don’t think you will do it twice or 2nd time you will get the opportunity to do it again . Suppose you are in great rush hour to submit sample, giving mail repeatedly to factory to submit the sample in certain date along with lots of phone call . Finally received it but factory made mistake to follow earlier comments what buyer has given . That means the sample is rejected & is not ok to send buyer . Again the sample is made following the comments but it was late one week . So all your production plan got delayed because of not to submit the sample due date . Actually from beginning you could avoid all the delay & wrong thing . If you could take just extra 15 minutes to check the change that buyer want in the earlier comment or before stitching you could visit factory & check everything that sample is going in right way it would help you to save time & energy . Take extra minute to do anything .

5) Do extra work just one day:
In your ‘to do list’ you got some task that has to be done by this week but you are engaged so much in some important meeting so could not able to work on weekly schedule . Now what can you do ? Use only one day to work extra hour in the week . Never think to do it every day . You can work extra hour at the last working day of a week so that the next day you can do relax & enjoy family . So a day for a week can be your extra hour to finish pending task . This will help you to minimize your work load .

6) Make a good relation with everyone to get job done early:
This is said that everyone is king in his own work place . May be the person is a lab in charge . As job routine he is bound to do what are all your requirement because owner assigned him to do job what merchandiser demand in related to lab issue . But this is also true he keeps schedule in his every day to do list as per queue . So you cannot ask for lab dip just in a day where as he has hundreds of lab making in the schedule . Here if you have good relation with the person it will be easy to get lab dip though you are not in the queue . So make a good relation to all the department even a person who is in a worker level . Never underestimate any one . Respect all to get respect from every one .

7) Utilize down time:
Usually success comes from the time which is not usually counted by the commners . Because to do extra work there are no alternative way except utilizing down time . Down time means – the time what you are just doing nothing or doing one more job simultaneously . Suppose you are just stucked in the traffic jam which is very common in our city life . It is often seen people are just seating in the jam & trying to blame the system . But if you want to use your down time ,this can be an opportunity for you . Take journal or book & start reading . That means all of your time can be used properly . On the other hand you can use down time in different way . May be you are having lunch .This may take 15 minutes to finish . During your lunch time you can listen radio news in your mobile . This will help you to get up-date information about what is happening around you . your busy life will not stop you to be up-dated in a new day .

8) Keep proper tracking whatever your are doing:
We are human being . So sometime this is not possible to keep everything in our memory . In the merchandising no one can you say everything is in tracking unless he follows some basic rules . The basic rules of keeping track is ‘put down notes’ in your excel sheet or note book . Make a excel sheet & put all your information whatever you receive every day . Put the date on the stuff what you receive from buyer & what you send to buyer . keep same information on the submitted items to avoid any kinds of confusion between you & buyer . Keep your sample / swatch in a place where anything may not be lost . Make sure to keep separately all your important items to be understood by everyone or to get it in your absence . You can follow below rules to keep tracking .
  • Put date on everything .
  • Up-date & review your excel sheet every day .
  • Keep hard copy of all your important mail . Because some time you may not be in net service when the information is required .
  • Put your excel saved in your draft mail to find the data available incase computer is got effected by the harmful virus .
  • Don’t forget to send a mail to any consignee whenever you are sending sample /swatch .
9) Keep all approval in hand :
Don’t miss any of your approval that received from buyer . Suppose fabric quality , sample or trims whatever comments on submission please keep in proper way so that it will not loss . If you have several submission on particular item that sent to buyer make sure to keep date & comment for each submission . This will help you not to be haphazard among the all submission .

10) Don’t miss to put anything on mailing correspondence :
Some time you may feel unnecessary to put things in the mail whatever discussion you did in phone or verbal communication with someone . In reality this is very important & never delay to put the content you discussed in a written document /mail to prove the conversation . Suppose a trim supplier confirmed you in a particular date to deliver the item over the phone . As you feel the commitment is definitely will be met so did not put the conversation in mail . But in the due date you get the supplier denied to deliver the item & ignored his commitment . So if you could keep the commitment in a written document it would be easier to hold him . Believe me this is most effective to make easy your job ,keeping things in mail .

11) Keep clean your desk :
A merchandiser has to do hundreds of job in a day so this is quite natural if his desk gets occupied by lots of stuff like paper , swatch , trims etc. Every day new items come to you & your surrounding is seeming a little store of fabric , sample & with others thing . You feel over loaded as your desk is overloaded by working stuff . How can you clean your desk to make free from all kinds dizzy materials ? This is really challenging for you rather than your daily job . Some time we feel keeping things on desk is not a problem & this is actually to get the things in hand . Believe me if your boss or others want to see anything in your obscene from the desk they might be puzzled & confused what to take & what to not take . So use only 30 minutes to keep clean your desk & put all the stuff in particular folder so that anyone can find any important item . This will make your job easy . Remember ‘The true competition lies is not what we do, but how we do it’.

12) Take suggestion if you are in trouble :
The universal truth is – two head is better than one head . That means if you are trying to do something counsel with other so that you can work more efficiently with less error . Never think you are the perfect one & no need to take suggestion from others . In other way this is called – cheer leader .Cheer leader is your boss , co-worker , friend so If you want to be in track & to do the correctly must discuss with fellow people. Definitely this will ease your job .

13) Filing & updating :
A merchandiser means lots of file & documents, so maintaining file for the each order & keeping the necessary stuff is very important . Actually this is little similar to the point ‘Keep clean your desk’. However this is specifically to put the thing in file properly . How your file will look ? where to keep it ? what name can be given to each file ? there are lots of issue that should have to take in consideration if are really interested to be a smarter merchandiser . To do your task in smart way you need to think about your file . Suppose where to keep it ? always try to keep your important file close to your hand so that you might not be haphazardly looking for your file when you need . Here some suggestion how to keep file –
  • Put a name for your file in bold letter .
  • Put all the information on top of the file ,example – style name , PO no , Qty , & a garment sketch .
  • Your file should be clean & need to keep all the paper in a chronological way .
  • For easy understanding you can use divider to keep separate the subject matter .
  • Use folder to keep different submission ,off course don’t forget to write date .
  • Use metal cliff so that the file can be use for long time .
  • If you receive revised PO please make sure to keep it in file & keep a cross mark on old PO .
  • Never remove any paper from your file ,if Pos are revised keep date on old file & write on top of it why this is changed . 

Factors to be Considered for the Selection of Correct Ring Traveller Size

Comprehensive Study on Ring Traveller

Md. Abu Sayed
Pabna Textile engineering college, Pabna, Bangladesh
Cell : +8801745214773

What are the different types of ring traveller and parts of traveller? Explain the factor to be considered for the selection of correct ring traveller size.

Mainly there are two types of traveller depending on the curvature of the traveller or the traveller circle. Namely –
  1. Regular traveller – When the traveller circle represents an arc of a true circle and the horns are more or less straight, the traveller is known as a regular traveller.
  2. Elliptical or oval traveller – When the traveller circle is the shape of an ellipse, the travellers are known as the elliptic travellers (more preciously as oval traveller)
Regular travellers again may be of various shapes depending on the height of the bows above the horns and are generally classified into two –
  1. Large bow regular travellers.
  2. Small bow regular travellers.
Again the radius of the side-circle of an elliptical traveller may be large or small and accordingly the oval traveller may be classified as –
  1. Large radius elliptic travellers.
  2. Small radius elliptic travellers.
The sectional parts of a traveller are –
  1. Bow – It is the curvature parts of the travellers.
  2. Horn – As the name implies these are the two ends of a traveller.
  3. Flange – The flange of a traveller is the openings between the two horns.
ring traveller

Factors to be considered for the selection of correct traveller size
There is no hard and fast rule for the selection of correct traveller size for a particular count. Wrong selection makes vast difficulties for satisfactory spinning conditions. Life of the ring depends very much on the proper selection of traveller size.

Count of yarn, Spindle speed, ring, size, bare bobbin diameter, lift of the bobbin, thread guide traverse etc. all should be taken into consideration individually as well as collectively for correct selection of traveller size, because there factors primarily influence the dynamical functions of the traveller. Fundamentally, a spinner should exercise own judgment in selection the adequate size of the traveller keeping in mind the following principle –
  • Wt. of the traveller varies inversely as yarn number – Higher the count, lighter the yarn and lighter the traveller to cope with the high speed running of the yarn to insert higher T.P.I. 
  • Wt. of the travellers varies inversely as spindle speed – Higher the spindle speed, lighter the traveller. Higher spindle speed used for higher count of yarn so the traveller is lighter also. Lighter traveller with higher spindle speed permits less wear of the ring. 
  • Wt. of the traveller varies inversely as the ring dia – With the increased diameter of the ring, the weight of the traveller is lighter. To maintain the constant surface speed of the traveller on the ring, its rate of travel to be increased with a lighter traveller. Higher the ring diameter, higher the angle of pull and lighter is the traveller. 
  • Wt. of the travellers varies inversely as the angle of pull – Higher the angle of pull lighter the traveller to maintain the constant winding tension on the yarn. The angle of pull depends on the diameter of the bobbin and ring. Higher the bobbin diameter lower the winding tension, lighter the traveller and similar with ring diameter.
What are the forces acting on traveller?
The principle forces acting on the traveller may be summarized as follow –
  • Retarding frictional forces against the passage of the thread at the thread guide and at the traveller.
  • Atmospheric resistance against the movement of the balloon.
  • Traveller weight.
  • Balloon tension.
  • Winding tension of the bobbin pull.
  • Retarding forces or frictional drag due to friction between the traveller and the ring.
  • Normal force due to the action of the ring against the traveller is centripetal force.
  • Reaction of the traveller against the ring flange is the centrifugal force.
The magnitude of the forces under items 1, 2, 3 are very small compared with the rest; they are usually of the order of the 1/3000 th of the centrifugal force and may be negated.

Author's  Blog:  Textile Apex (

Ergonomic Workplace Evaluation in Ugandan Apparel Plants (Part-8)

Ergonomic Workplace Evaluation in Ugandan Apparel Plants (Part-8)
Tebyetekerwa Mike
Dept. of Textile & Clothing Technology
Kyambogo University
Kampala, Uganda
Tel: +256(0)773770312 // +256(0)701181383

.......Previous Part


5.0 Introduction
This chapter presents the recommendations and conclusions of the Uganda apparel plant workplaces conducted in the ergonomics point of view and attempts to give solutions to problems found out as a result of the study.

5.1 Recommendations

5.1.0 Proper tools
Tools should be appropriate for the specific tasks being performed. Tools should allow the worker to keep the hands and wrists straight. (Ahasan, 2002)

5.1.1 Proper work postures

For seated and standing work, the height of the workstation should allow workers to function with elbows at 90 degrees. During seated work, if a good back support is not present or used, static postures occur which results in constant use of the back muscles. It is important to adjust the workstation in order to allow the worker to use the backrest. (Ahasan et al, 2000)

It is also important to adjust the worker’s chair to allow duties to be performed with their bodies in comfortable positions. The workstation and chair should be positioned so that the worker’s knees, hips, and elbows are at 90 degrees, which will reduce stress on the body. There should also be enough room to allow the worker to change their sitting position throughout the day. (Bongers et al, 2002).

Static postures can also occur during standing work. If the worker stands in one position for long periods of time, muscles of the back and legs will be constantly activated. This can lead to increased fatigue, and decreased blood circulation to the legs. During the day, workers should try to walk around to allow their blood to flow. As well, workers should try and sit for short periods of time while working to give their leg and back muscles a rest. (Blader et al, 1991)

Awkward wrist postures are one of the major causes of cumulative trauma disorders (CTD) such as carpal tunnel syndrome (CTS), tendinitis, and muscle strains. Awkward wrist postures are those which take the wrist away from the neutral position. Neutral position is when the hand is in line with the forearm. The workstation should be adjusted and the worker educated on awkward wrist postures, their harmful effects, and the signs and symptoms of CTD’s. (Chan et al, 2002)

5.1.2 Keep repetitive motions to a minimum
Workstations or tasks should be redesigned to reduce the number of repetitive motions that must be performed. To prevent ergonomic injuries workers should be encouraged to rotate tasks or take frequent, short breaks to stretch and relax muscles. Work stations should allow enough space for the tasks have appropriate working height, and provide proper seating. Manufacturing tools and machinery used in the firms should incorporate ergonomic design principles and should not require an excessive amount of force to operate. Some tasks should be automated or redesigned to eliminate repetitive movements and musculoskeletal injuries. (Halpern et al, 1997)

5.1.3 Use safe lifting procedures

Workers should avoid lifting objects that are too heavy. Use more than one person or a mechanical device to reduce the load. The workstation should not require the workers to lift objects above their heads or twist their backs while lifting. (Halpern et al, 1997)

5.1.4 Get proper rest
The workers need to rest their body and mind in order to prevent injuries. Workers should give their muscles a rest during coffee breaks, lunches and weekends by doing something different from what they do at job. For example, if a worker stands all day, while performing a job he/she should sit down to rest the legs and feet during the breaks. If a worker sits down, when working, he/she should stand up and walk around during breaks to give the back a rest and to increase circulation in the legs. By doing this the musculoskeletal injuries can be prevented. (Chan et al, 2002)

5.1.5 Other things to consider

Garment workers can avoid eye injuries by using proper shields on high-speed sewing machinery or safety glasses where appropriate.

Furniture and other equipment used in the plant should be ergonomically engineered to prevent injuries. The seats should adjust easily, have padded seat, have adjustable backrest provide lumbar support and have casters. The equipment and workstations should be adjustable, give sufficient space for the body and be used by both left-handed and right handed with ease.

Also, adequate task lighting at individual workstations can prevent eyestrain. Some garment manufacturing equipment can be very loud, so proper hearing protection may be necessary.

Because a garment factory uses many heated processes, it is important for workers to avoid heat stress by labeling and guarding hot surfaces and drinking plenty of water during their shift. Proper ventilation can help to reduce ambient temperatures and ensure worker comfort.(Sarder et al, 1996)

Training of the workers on the proper use of machines and equipment is very important, proper posture, proper work method, when and how to adjust workstations and about safety measures and first aid.(Vihma.T, 1981)

5.2 Conclusions

This study examined the ergonomic work conditions in the apparel manufacturing plants in Uganda. Questionnaire survey responses and observations of the physical workplace pertaining the working conditions showed clear evidence of work practices, workplace conditions and equipment designs that were detrimental to productivity, health and safety.

The garment industry should therefore focus and develop a good working conditions to reduce the injuries created to their workers since there is ample room for ergonomic improvements in the clothing industry. With proper training and instruction, machine guarding, personal protective equipment and ergonomically designed work systems, garment workers can manufacture products in safe and healthy workplaces.

It seems that the tradition of management, owners and workers themselves know and understand that the ergonomics conditions in the plants are worse but they are ignorant about the solutions. Therefore there is need for ergonomic interventions to make changes that have been considered. It is, therefore, logical, as done in this study, to suggest changes that are modest, for gaining acceptability to management.

Recommendations made to management in this study that included furniture and other equipment improvements were combined with improved line balancing of the manufacturing process. The implementation of these recommendations should yield significant improvements in productivity and the effects on the workers over a relatively short period of time.

Unless the work culture changes significantly, it would always be difficult to implement changes that alleviate suffering and ill health among workers in societies where unemployed people wait in abundance for a chance to work, and where their introduction into the workplace is seen as an alternative to spending money and other resources to improve work conditions

My main ojective was to evaluate the working conditions in the garment plants of Uganda from an ergonomics/human factors perspective and to suggest possible solutions to deal with observed problems in order to avail a better working environment with minimum or no threats to the workers.

Since the problems have been identified and solutions stressed out in the light of the problem. Therefore if solutions are taken, the workplace for the worker should have a decreased risk of injury and also to improve the link between the worker and their environment.


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