Footwear Industry Bangladesh - A Comparative Study
Footwear Industry Bangladesh - A Comparative Study
Footwear Industry Bangladesh - A Comparative Study
INDUSTRY OF BANGLADESH
A C O M PA R ATI V E S T U D Y O N T H E B U S I N E S S M O D E L S O F F O O TW E A R C O M PA NI ES
Prepared for
Mr. Sheikh Morshed Jahan
Associate Professor
Course Instructor: Bangladesh Studies (G201)
Prepared by
Group 5, Section A, BBA 20th
ZR-05 MD. Mazharul Islam
ZR-08 Abashesh Biswas
RH-09 Tashfia Rawnak Anika
ZR-15 Fahmin Rahman
RH-19 Fableeha Bushra Chowdhury
RH-28 Syeda Shehtaz Hasib
ZR-31 Nishadul Haque Nihal
ZR-32 Rakib Khan
ZR-39 Sabbir Hossen
RH-48 Sadia Samira
ZR-60 Sajeed Alam
ZR-62 Ahnaf Ahmed
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Dear Sir,
As commissioned under the term paper submission of your course, we are submitting the
attached report titled Dynamics of the Footwear Industry of Bangladesh - A Comparative
Study on the Business Models of Footwear Companies. The major areas of analysis in our
report include a detailed analysis of six of the major footwear companies operating in
Bangladesh (local and international) in terms of manufacturing, sourcing and retail ; an
analysis of the export-oriented operations and marketing activities of these companies ; and
some company-specific case studies.
In completion of this report, we would like to thank you for the opportunity to work on this
assignment as it has helped us explore a key industry in our economy in terms of domestic
consumption and international presence. We hope you find this report satisfactory.
Sincerely,
______________________ ____________________
________________________
MD. Mazharul Islam ZR-05 Abashesh Biswas ZR-08 Tashfia Rawnak Anika RH-09
___________________ _____________________________ _________________
Fahmin Rahman ZR-15 Fableeha Bushra Chowdhury RH-19 Sabbir Hossen ZR-39
_______________________ _______________ ________________ ________________
Syeda Shehtaz Hasib RH-28 Rakib Khan ZR-32 Sadia Samira RH-48 Sajeed Alam ZR-60
_______________________ _________________
Nishadul Haque Nihal ZR-31 Ahnaf Ahmed ZR-62
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CONTENTS
Executive Summary...............................................................................................6
1.
Introduction....................................................................................................7
1.1 Purpose........................................................................................................8
1.2 Objective of the Report..................................................................................8
1.3 Scope..........................................................................................................8
1.4 Limitations...................................................................................................9
1.5 Methodology.................................................................................................9
5. Arbana............................................................................................................37
5.1 Company Overview......................................................................................37
5.2 Supplies.....................................................................................................37
5.3 Manufacturing.............................................................................................37
5.4 Distribution, Retail Outlets and Exports..........................................................38
5.5 Product Portfolio..........................................................................................38
5.6 Case: An Architect of Footwear......................................................................38
6. Fortuna Leather Craft Ltd..................................................................................40
6.1 Company Profile..........................................................................................40
6.2 Supplies.....................................................................................................40
6.3 Manufacturing.............................................................................................41
6.4 Exports......................................................................................................41
6.5 Product Offerings.........................................................................................42
6.6 Retail Outlets..............................................................................................43
6.7 Case: Fortuna Leading Bangladeshs Footwear Industry with Visionary Thinking. .43
7. Leatherex........................................................................................................46
7.1 Company Profile..........................................................................................46
7.2 Supplies.....................................................................................................47
7.3 Manufacturing.............................................................................................49
7.4 Distribution.................................................................................................49
7.5 Exports......................................................................................................50
7.6 Product Offerings.........................................................................................50
7.7 Retail Outlets..............................................................................................50
7.8 Case: Evolution of Leatherex- All the Right Moves............................................51
8.0 Bay Emporium...............................................................................................53
8.1 Company Profile..........................................................................................54
8.2 Supplies.....................................................................................................54
8.3 Manufacturing.............................................................................................54
8.4 Distribution.................................................................................................55
8.5 Exports......................................................................................................55
8.6 Product Offerings.........................................................................................55
8.7 Case: How Bay positioned itself in the market.................................................56
9.
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EXECUTIVE SUMMARY
The footwear industry of Bangladesh, due to its rapid growth in demand both in the local
and global market, is now considered the next ready-made garments sector. With around
41% of the export earnings coming from the leather-based footwear industry in the
fiscal year 2012-2013 (Export Promotion Bureau, 2013), it is not very surprising that
entrepreneurs are entering this sector in great numbers. The low entry barrier and the
high demand from the consumers, is only facilitating the new ventures, and the industry
is well set to expand in the future. Footwear companies like Arbana Fortuna, Leatherex
and Bay Emporium have entered the market in a time span of less than a decade.
Consequently, the footwear industry has been experiencing an annual growth rate of
21% according to Leather Goods and Footwear Manufacturers and Exporters Association
(LGFMEAB).
When it comes to the local footwear market, Bata is still considered the family brand
and most people believe it to be a local company because of its domestic approach.
Starting its journey in 1962, this multinational company with outlets in over 90
countries, enjoys revenue of around 5 million a year. Following Batas lead, Apex started
in the early 2000s with a view to take away a sizeable portion of Batas market share.
Both the companies employ similar business strategies like offering a wide range of
products to reap the benefits of price discrimination and reach out to a larger target
market.
In a time span of less than a decade, footwear companies like Arbana, Fortuna,
Leatherex and Bay Emporium have entered the market with a different aim in mind.
These companies chiefly produce leather footwear and other accessories. Their footwear
is more customized, hence more differentiated, and cost more than Bata and Apexs
footwear. However, customers still tend to value these locally made creative products,
and companies like Arbana, boasts their 100% hand crafted designs. Arbana also sells
with its own brand name in Middle Eastern countries like Dubai.
Vertical linkage in the latter group of companies is a common phenomenon. Backward
and forward integration helps these companies coordinate the demands of the production
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line expansion, actively control production costs, reduce material lead time, and master
production cycles to deliver value to its customers. Most of these companies have a zero
or one level supply chain, hence, are able to offer their customers competitive prices and
superior buying experience.
1.
INTRODUCTION
This term paper is prepared with an intention to meet partial requirement of the course
Bangladesh Studies. The paper focuses on the dynamics of the footwear industry of
Bangladesh. Government of Bangladesh has identified the Leather sector as one of the
thrust sectors. Leather sector earns a substantial amount of foreign currency every year
through export of leather and footwear. Footwear industry, which constitutes a significant
portion of the leather industry, is now playing an important role in the global market.
Leather processing is an old manufacturing sub-sector in Bangladesh with a long
heritage of over six decades. Availability of indigenous raw material (hides and skins)
facilitated the setting up of the industry in early 1940s in the then East Bengal. During
Pakistan period (1947-1971), the industry was dominated by non-Bengali migrants from
India, who had the knowledge and the know-how of leather processing industry. At that
time, leather processing was limited to the production of wet blue leather (semiprocessed tanned leather) and the non-Bengali traders exported a large part of the
produce to West Pakistan for further processing and production of leather goods. A few
small tanning units belonged to Bengali entrepreneurs who processed leather mainly for
the domestic market (Ali, 2011).
After the independence of Bangladesh, the government took over the tannery industry
abandoned by the departing non-Bengali entrepreneurs but had limited success in
operating them under the public sector. Export of processed leather consisted almost
entirely of wet blue leather till 1980-81. After 1981, a number of policy support
measures aimed at raising the level of value addition in the industry provided incentive
for new private investment in leather industry. The ban on export of wet blue leather in
June 1990 led to the setting up of modern leather tanning units for the production of
crust leather (tanned leather after further processing of wet blue leather) and finished
leather and this was followed by new investment in leather goods industry, particularly
leather footwear (International Monetary Fund, 2000).
There are three broad components of the leather industry (i) Leather tanning
(Bangladesh Small and Cottage Industry Corporation, BSIC Code, 1911), (ii) Leather
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footwear (BSIC Code 1921) and (iii) Other leather products such as handbags, carry
bags, wallets, cases etc. (BSIC Code, 1912). According to Export Promotion Bureau,
Leather footwear accounted for 41% of export earnings from leather and leather
products in 2012-13, while the share of leather and other leather products were 39%
and 20% respectively. Thus notwithstanding its small size, leather industry in
Bangladesh seems to have undergone significant transformation during the past two
decades from a low value addition tanning activity to an exporter of leather footwear and
leather goods (Ahmad &Bakht, 2010).
1.1 PURPOSE
This report was done to study the business models of some of the popular footwear
companies in Bangladesh in order to understand the overall dynamics of the footwear
industry by evaluating their value delivery processes and particular issues true for each
of them.
1.3 SCOPE
This study encompasses some notable names in the footwear industry of Bangladesh.
Because the footwear industry is closely intertwined with the leather industry and
products of the two are perceived to be substitutes, the report refers to both these
industries in the discussions. Some of the companies studied for this report sells both
leather and non-leather footwear, while other solely produce leather footwear, but since
all these companies target the same or similar segments, the companies business
models are comparable.
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1.4 LIMITATIONS
Some restraints that were faced at the time of preparing the report are given below:
business
Only six of around fifty footwear names in the industry, were studied
1.5 METHODOLOGY
For preparing this report, information was gathered from the following sources:
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markets in EU and Japan. Japan and Germany are now the biggest markets for
Bangladeshi footwear but US buyers are increasingly showing interest in sourcing from
Bangladesh.
This growth in footwear exports has come as a blessing in disguise at a time when
leather exports have fallen by a massive 18 percent in the period under review. Experts
attribute the growth in footwear exports, thanks to machineries imported from Italy that
is trusted for its quality output. In recessionary trends, high-priced products tend to
register a negative growth, as consumers tend to shy away from them in preference for
value for money items. In this scenario, it is a golden opportunity for the leather and
footwear sector to increase its global market share by producing simply day-to-day
footwear at affordable rates.
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, but this scenario is quickly changing.
now
Similar prices in among shops, hence high competition and better consumer
experience
Weaknesses:
Designs from
not
company
to
company
do
vary much
Opportunity:
conquered
Consumers preference of local, high quality products, over cheap, Chinese and
Burmese imports
Getting media attention and therefore attracting resources like capital, land and
labor
Threat:
Political unrest
Volatility of the world economy and hence demand for footwear manufacture in
Bangladesh
Maturity of the industry from infancy
Government withdrawing aids gradually
Threat of removal of international trading aids
Vietnam excelling at productivity and low cost footwears
Ongoing law suits against the leather cottages in Hazaribagh
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with the reaction from existing competitors that the entrant can expect.
The major sources of barrier to entry include-
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name and customer loyalty. Thus new entrants have to invest a lot to build their
own brand name.
Capital Requirements: They need to invest large financial resources in order to
face the barriers to entry particularly if the capital is required for risky or
unrecoverable up-front advertising or R&D. Capital may be necessary not only for
production facility but also for covering start-up losses. The leather footwear
industries currentlyhave lots of financial resources by which they can now even
enter any new industries. Such as, Fortuna has already entered in to food
industries named Fortuna Fried Chicken (FFC).
Access to Distribution Channels: It refers
to
the
access
to
favorable
new entrants must have strong and secured distribution channels of their own products
to enter and compete into the industry. O
Force 2: Threats of Substitute Products
Substitute products are those products that can perform the same function as the
product of the industry. There are a lot of substitute products of leather footwear like
footwear of Rexine, Plastic, Rubber, and Jute. These substitute products give a great
competition to the footwear in many sectors. Such as-
footwear
is
comparatively
more
expensive
than
other
substitute products like, rexine, plastic, etc. Rexine is a product which fulfills
almost all there quirements of leather and it looks quite similar.
Number of Substitute Products Available in the Market : There are many types
of footwear in the market but the major substitute of leather footwear is rexine,
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Plastic,Rubber, Fabric, Jute, etc. Major portion of customer from leather footwear
are diverting to Rexine footwear because it looks quite similar to leather but is
less expensive.
Force 3: Intensity of Rivalry among Existing Competitors
Rivalry among existing competitors takes the familiar form of jockeying for position by
using tactics like price competition, advertising battles, product introduction and
increased customer service or warranties. Rivalry occurs because one or more
competitors either feels the pressure or sees the opportunity to improve position. The
leather footwear industry is thus facing such rivalry among existing competitors. Factors
that increase competitive rivalry among existing firms include:
Numerous Competitors with Roughly Equal Size & Power: If there are more firms
within an industry; there is an increased competition for the same customers
and product resources. There is even greater competition if industry players are
equal insize and power, as rivals compete for market dominance. It is seen that in
the leather footwear industry, most of the companies from 109 firms are of equal
size and power which increased competition for the same customers and product
resources such as Bata, Apex, and Fortuna etc.
Slow Industry Growth: When an industry is growing rapidly, firms are able to
increase profits because of the expanding industry. When growth slows down and
industries reach the maturity stage of the industry lifecycle, competition increases
to gain market share. This is an example for Bata which is leading the market
from a very long time. It reached to maturity stage and now competes to gain
market share. Apex is also reaching the same stage gradually.
High Fixed or Shortage Costs: In industries where the fixed costs are high, firms
will compete to gain the largest amount of market share possible to cover the
fixed costs. This is what every firm is trying to reach the fixed costs and shortage
its costs in the leather footwear industry.
High Exit Barriers: When high exit barriers exist; firms will stay and compete in
an industry longer than they would if no exit barriers existed. In leather
footwear industries of Bangladesh exit barriers condition varies from company to
company. For example Bata, Apex and other established existing companies
cannot easily cross the barriers, considering the major sources such as
specialized assets, fixed costs of exit strategy, interrelationships, emotional
barriers, government and social restrictions. On the other hand exit barrier is low
for those new firms entering into the industry.
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Buyers are Concentrated or Purchase Large Volumes Relative to Seller Sales: The
leather footwear sellers are supplying footwear to a large number of consumers.
Theconsumers who are fond of leather, always use or purchase leather footwear
and alsoleather footwear are also use as a formal dress-up. In this scenario, the
purchasers aremuch larger and so can exert pressure on the suppliers.
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Where very few products are chased by a large number of buyers there poses a
bargaining power of supplier. In Bangladesh, there are many leather footwear industries. As
we all know there are many steps needed to prepare the leather before manufacturing. This
increases the production cost. Besides there are some other barrier like water effluent
treatment plants delay in payment by the buyers, slow process in sanctioning funds by
bankers, unauthorized labor absenteeism, poor quality of equipments, political condition and
government restrictions. Sometimes it is harder to fight back with all these problems. As a
result the price of the product either increases or become stable at previous price. On the
other hand the substitute products, they do not have to face all these problems. They are
independent to set the price at a lower rate and consumers find the substitute product with the
same features with a lower cost, which grab the leather market customers and divert them to
other substitute product market. The conditions making suppliers powerful are largely the
inverse of those making buyers powerful. A supplier group is powerful if:
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With Bangladesh having developed a strong position amongst European and US buyers,
many countries are already having eager to evaluate the future potential of this
country.(Bangladesh Ready Made Garments Landscape: The Challenge of Growth)
with this statement in mind it can be said that Bangladesh is going through a booming
phase where not only can it expand its RMG sector but also venture into new sectors to
reach the big market.
Currently Bangladesh exports leather, leather goods and footwear is valued at around $1
billion a year which is about only 0.05% of the global market. Some of the companies
already export standard quality products which are highly appreciated by the export
countries. As a result the potential for this sector to grab a large share in the global
market is very promising.
Some say that after RMG, Footwear Industry will be the next best thing for Bangladesh.
Bangladesh RMG is the second largest exporter of RMG which is approximately 80% of
the total export. But it is evident that the condition of the RMG sector has grabbed the
attention of millions of people around the world and sadly their perception about
Bangladesh RMG is somewhat negative especially after the Rana Plaza incident. It has
been evident for the policy makers that it will be difficult for us to move on to the next
phase of Bangladeshs economic progress without developing new industries. Ifty Islam,
Managing partner at AT Capital.
This is where Footwear comes in. Some of the factors that will highly help this sector to
grow is the availability of the elements, raw materials and cheap labor (high working age
population). But the major drawback that is stopping this sector to flourish are the
nonexistent environmental friendly tanneries. According to some analysts, Bangladesh
will be able to earn at least $5 billion in exports from leather, leather goods and footwear
in the next decade if it can properly address health, environment and compliance issues
in the sector. The only solution to this is the relocation of the tanneries. This step will
help
the
footwear
industry
to
go
through
boost.
The benefits that the footwear industry at the moment poses are immense. The benefits
as a whole will be able to take the country to the next phase in the global market.
Studies show that if the desired export amount is reached then the country will be able
to increase domestic manufacturing output by 9.2 percent and agricultural output by 6.7
percent according to a 'simulation exercise' conducted by Khondker and M Abu Eusuf, a
professor at the development studies department at DU. The reason of increase in
agricultural units will be because of the future increase of the demand of livestock. Also
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according to this study it shows that approximately 4.4 million jobs will be created and
this will lead to a high economic growth.
The high potential of footwear industry has already been addresses to. Due to relocation
Tannery owners require money and for this reason government is asked to take
necessary steps to help the owners. First step could be long- term loans with single digit
interest.
Tannery owners also urged the government to provide long-term loans at single digit
interest rates. In par with that the owners are also urged to maintain the standards from
the beginning. Each tanneries also need proper equipments to increase quality and
efficiency. A total of 127 tanneries out of 155 already submitted their factory layoutto
Bangladesh Small and Cottage Industries Corporation (BSCIC), the implementing
agency, of which 85 of them are approved. After approval these factories are subjected
to loans from the government.
If the footwear industry is given importance by solving problems from the core with a
fresh start then the future of this industry will hold a strong position in the economy of
Bangladesh.
3. BATA
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The Bata Shoe Organization was established in August 24, 1894 in Zlin, Czechoslovakia
by Tomas Bata, along with his siblings Antonin and Anna. Although a new venture, the
Bata family had been involved in eight generations of shoe making which spanned over
three hundred years. The Bata business aimed at becoming one of the first modern shoe
manufacturers, a team of stitching workers and shoemakers creating footwear not just
for the local town, but also for distant retail merchants. This departure from the
centuries-old tradition of the one-man cobblers workshop was a brand new concept,
creating an entirely new industry. This industry has developed exponentially over the
years and currently Bata operates in over 70 countries under three strategic business
units: Bata Europe (based in Italy), Bata Emerging Market (Latin America, Africa and
Asia Pacific) and Bata Protective (worldwide B2B Operations).
Bata estimates that it serves more than 1 million customers per day, employing over
30,000 people, operates more than 5,000 retail stores, manages 27 production facilities
and maintains a retail presence in over 90 countries. Although the company originated in
Czechoslovakia, family migration to Canada has shifted the company heritage and
culture to a Canada based company. The global headquarters of Bata are in Lausanne,
Switzerland. Thomas G. Bata, grandson of Tomas Bata currently heads the organization
and the Bata family still maintains a majority of company ownership.
Bata started its operations in Bangladesh in 1962 and has grown to become the market
leader in the local footwear industry. Bata Bangladesh is a public limited company, with a
51% to 49% share with the Bangladesh government. The company is also one of the
largest taxpaying corporate bodies contributing Tk. 1.2 billion in 2009, which represents
approximately 70% of tax paid by the entire footwear sector of Bangladesh. Currently
Bata Bangladesh operates two manufacturing facilities, one in Tongi and the other in
Dhamrai. With a production capacity of 110,000 pairs of shoes daily, the company also
has a modern tannery facility with an output of 5 million square feet of leather annually.
Annual shoe sales currently stand at slightly more than 30 million with a turnover for the
year 2009 of Tk 5 billion.
The company also maintains a diverse brand portfolio with each brand catering to a
specific consumer segment. These include: Bata, Ambassador by Bata, Bata Comfit, Dr.
Scholl, Hush Puppies, Marie Claire, Nike, Bubblegummers, Sandak, Weinbrenner, Bfirst
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and Power. Based on local demand, personalized brands are also created such as
Mocassino by Bata and the company is continually developing marketing intelligence to
consolidate its market position.
The
value addition starts from the core values of Bata categorized as the Bata leadership
points. Furthermore, each segment of the supply chain (sourcing, manufacturing,
distribution and retailing) focuses on continuous value addition.
3.3 SUPPLIES
Bata Bangladesh procures leather from two sources:
About 20 to 30 per cent of raw materials are sourced from Batas Dhamrai facility. This
accounts to about 5 million square feet of leather annually. Also, the specific tannery
facility at Hazaribagh that Bata contracts with maintains an efficient delivery system of
leather within 7 days of order. In the case of inventory management, Just-in-time
inventory management practice is followed.
Artificial leather, plastic and rubber materials are procured from foreign sources, mainly
Thailand and China, on a contractual basis.
3.3 MANUFACTURING
Bata Bangladesh has four different sources of manufacturing: own facilities, satellite
facilities, outsourcing and imports.
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i. Own facilities:
Bata Bangladesh has two factories, one in Tongi and the other in Dhamrai. The combined
capacity of the factories is 110,000 shoes daily. All the rubber and related materials
production and assembling is done in the Tongi factory, whereas, leather products are
been manufactured in the Dhamrai factory. About 92% of all Bata products are produced
in these two factories. These production facilities not only have state-of-the-art
manufacturing equipment imported from Singapore and China, but they also maintain
environmental safety through effluent treating plants (ETPs).
ii. Satellite:
There are some satellite production factories, which produce solely for Bata with the
production facility of those factories set up by Bata Bangladesh itself. About 4% of
footwear production is from satellite sources.
iii. Outsourcing:
Bata Bangladesh outsources a very small part of its production to different small shoe
industries mainly from the Dhaka region. The quality and the specification at these
production facilities are ensured and strictly evaluated by the Bata technical team. The
participation of outsourcing in the companys business is 4%.
iv. Import:
Bata imports part of its products, mainly the global flagship brands like Hush Puppies
and Nike, to keep up with the market trend and demand. In spite of high import duties
of around 101%, imports for such products are still conducted.
3.4 DISTRIBUTION
The distribution channel of Bata Bangladesh operates as follows:
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1. The physical distribution starts from sourcing the raw materials and delivering
them to the production facilities at Tongi and Dhamrai.
2. From there, the manufactured shoes are sent to the CDC (Central Distribution
Center) located in the Tongi factory. Product packaging is done at the Tongi
facility.
3. After receiving the products, completing the packaging and allocating quantities
based on the destination, the products are delivered from the CDC to the
respective destinations via Batas own transportation vehicles. Bata has trucks,
pickup vans and covered vans for transportation. The CDC gets the daily update
and the last situation of retail stores. In case special orders are placed on
demandable products, an area manager ensures the availability of the products
into the specific stores through proper channeling. For instance, if products are
needed within 24 hours it is usually informed to the area manager and based on
the information, he/she informs distribution manager at CDC. The CDC then
supplies the product lot to retail stores over the phone. Another way is to follow
the inter-transfer system, which involves getting the products from a nearby
store.
There is a separate process for distributing to Batas own retail stores and to those of the
wholesalers and dealers. An equally extensive network of depots and dealers
supplements this extensive retail network.The goods for agencies and stores gone
straight to the store headquarter and goods for others gone to the 13 depots around the
country from where they collect the goods.Bata has 13 Wholesale depots covering
Bangladesh. Under these depots 453 RWD (Registered Wholesale Dealers) and 670 DSP
(Dealer Support Program) stores are operating.
In retail, Bata Bangladesh operates through a chain of exclusive own and franchise
stores.Ithas a network of 265 retail outlets located strategically in different parts of the
country at prime locations.70% of Batas sales are from its own retail outlets. Besides
there is a network of about 500 exclusive wholesalers who service about 300 retail
stores all over the country.This increases widespread availability of Bata products and
increases efficiency in distribution and delivery of value to the end consumers.
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Product designs are mostly imported from regional Bata subsidiaries. However, Bata
Bangladesh maintains a market intelligence wing to monitor demand patterns. In fact,
one of the notable activities of the market intelligence include introduction of Mocassino
by Bata, a range of loafers in order to meet the growing demand of loafers in
Bangladesh. In terms of brands, Bata maintains brands in three broad categories:
children, women and men. Following are some of the notable brands offered by Bata
Bangladesh:
The best product: Bata companies offer customers fresh, fashionable footwear
and accessories, designed specifically for the needs of the local market. The shoes
are made from quality materials. In Bangladesh, high quality leather from Batas
own tannery and selected tanneries is used. Furthermore, even manufacturing
equipment is state of the art and sourced from China and Singapore. Plastic and
non-leather items for shoe manufacturing are imported from selective companies
iv.
customer policy for sales representatives. This includes the following steps:
Welcome every customer.
Ask him or her about the need.
Show him or her three types of demanded product:
- Customers own choices
- Similarto that choice
- Highest pricing product
Try to add-on selling (Socks, shoe polishand leather rmade bag).
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v.
The best value and quality: Through the efficient sourcing and distribution of Bata
products, cost and quality are firmly regulated. Bata maintains a Central
Distribution Center (CDC), which regulates efficient delivery systems across the
and
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definitive for school going students and in terms of quality; none dismiss the authenticity
and craftsmanship of Bata footwear.
In the case of catering to the aesthetic factor and appeal that drives footwear purchase
decisions in consumers, Bata has a market intelligence wing, which analyzes consumer
trends and market demographics. On the basis of that, the results are forwarded to the
design and strategic divisions, which then decide what range of products to import and
design. For instance, the increasing demand for loafers in Bangladesh has led to the
introduction of Mocassino by Bata, Batas very own chain of loafers. When globally, the
Converse All-Star shoes became a fashion icon among the youth, Bata introduced its
own range of canvas shoes, North Star, to tackle competition. Also, with growing
consumer purchasing power and demand for premium footwear, Bata has had immense
success through the introduction of Hush Puppies. In fact, Hush Puppies also has its own
retail outlets due to increasing demand for the brand. Bata also frequently introduces
trade promotions and brings in new product designs to keep consumer inflow intact.
One of the greatest successes of Bata has been its geographic reach. It is the first
footwear company to have introduced wholesaling and dealership programs to allow
franchising of the brand. A lot of outlets in the rural areas have thus been established by
these franchisees, increasing the scope of market coverage of Bata, something which
none of its competitors possess. Also, Bata is the only footwear company to conductthe
segmentation of retail outlets according to profiles of different market segments and the
introduction of novel concepts such as Bata City Stores. These selective outlets, in
conjunction with other types of outlets such as Bata Bazar and Bata Family Stores, are
adding a new level of consumer satisfaction. The City Stores incorporate spacious floor
space allowing a comfortable shopping experience, modern interior dcor enriched with
novel shelving systems, fittings, fixtures and lighting that can be found in the large retail
shops in the Far East and Europe.
Overall, the company is not only building its brand by covering as many diverse
consumer segments as possible and keeping up to the pace of consumer trends, it is also
increasing accessibility to the brand. The segmentation of outlets has also led to marked
success in brand coverage, which has provided it an immense competitive advantage
over its biggest competitors, who have almost no commercial activity within Bangladesh
outside the capital and Chittagong. Bata hence, continues to retain its stronghold over
the Bangladesh footwear industry.
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4.2 MANUFACTURING
Apex Adelchi Footwear Bangladesh Ltd has total 304,545 square feet of factory area
complied with Global Standards of Footwear Production and imported machinery from
Germany, Italy and Taiwan. In the year 2012, Apex Adelchi Footwear Bangladesh Ltd
utilized its 92.03% of the whole production capacity. It manufactures 5000 pairs of
leather shoes everyday while its competitor Bata produces only 4000 pairs.
4.3 SUPPLIES
Role of suppliers in the Competitive Strategy
The level of efficiency and responsiveness the supply chain can achieve is affected by the
sourcing decisions taken, which makes it crucial to the production process. Most of the
leather is procured from Apex Tannery Ltd. to ensure best quality and increase
responsiveness. When located within Dhaka City, Apex uses private carrier to deliver
product from central distribution center (CDC) to Gallerie Apex. On the other hand if it is
located outside of Dhaka city, it uses package carriers or rent transports from third party.
For export, it also uses third party, like Cost and Freight Forwarding Agents, to achieve
economies of scale.
Purchasing Strategies
A firms competitive advantage no longer depends solely on its competency in providing
a competitive range of offerings. It also depends on the firms skill to establish superior
purchasing strategies in complex inter- organizational settings of numerous suppliers.
Firms are no longer able to develop major product or service innovations alone because
of the dispersion of knowledge and technological resources driven by organizational
specialization. In addition, the growing need for greater effectiveness to focus on its core
competencies leads to the externalization of the activities to partners.
Apex Adelchi Footwear maintains both single and multiple sourcing strategies. It looks
for single sourcing strategies when it has only one supplier for each product and service.
It seeks scale advantages through lower cost products in a dyadic relationship. Multiple
sourcing strategies are adopted when the buyer systematically utilizes several suppliers
for each product and service. Apex considers quality foremost here. Those who maintain
quality gets most of the business from Apex.
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Apex Adelchi Footwear procures its raw materials from both local and foreign sources. It
collects leather from Apex Tannery Ltd. It imports soles, line lather, stickers or
ornaments, glue, shoelace, and yarn from China and India. It import directly from the
manufacturers of raw materials who meets quality and its requirements. It also imports
by using local third parties. In case of procurement of raw materials, it only focuses on
the quality. It does not maintain partnering, relationship buying or collaborative network
with its suppliers. It maintains transactional exchange through the following strategies:
Single purchase
Focus on quality
One time purchasing event
Significant purchase
After sales experts
Maintaining services
Quality is always prioritized, and Apex Adelchi Footwear is ready to procure leather from
suppliers at a relatively higher cost if the high quality is assured. When suppliers
maintain their reliability in ensuring high quality over a long time, then it repurchases
from these suppliers for a longer duration.
Apex Adelchi Footwear always maintains its relationship strategy through the following
terms:
Strategic procurement
Key partner network
Decreased no suppliers
Better knowing of chosen suppliers
Updated product versions
Mutual knowledge transfer
It takes two months to get raw materials arrived its factory from any country since it was
ordered. It uses both air and ocean for importing raw materials.
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Eid ul Adha provides a high amount of the leather used in the production of Apex Adelchi
Footwear. Most of the leather used during the year is obtained during this period, and it
is absolutely essential to utilize all the available resources in gathering leather from as
many sources as possible.
In the recent times, Apex Adelchi Footwear Bangladesh Ltd is concentrating on designing
new and innovative products. As a result, it has come up with a new athletic shoe named
Aetrex Performance Footwear. This sports shoe is very comfortable and at the same time
uses top class design performance using state-of-the-art technology and materials.
Apex Adelchi Footwear Bangladesh Ltd designs its products based on the following
categories;
Category
Category
Category
Category
A: The best
B: Better
C: Good
D: Moderately good
Apex Adelchi Footwear Bangladesh Ltd also sells some high end footwear products
representing the brand. Some of these products are; IT (Italian) Project, ID Shoe,
Franco and HW (hardy worker).
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4.5 DISTRIBUTION
Ordering System
Gallerie Apex orders its required products to the Central Distribution Center (CDC),
situated at Tejgoan in Dhaka City, by completing a Special Requirement Form. Store
manager fill up this form mentioning the code of the product, quantity and other things.
The order is made on a weekly basis and placed early enough to avoid running out of
stock. This form is sent to CDC either by the sales force or a courier service. CDC
accumulates several requirement forms of Gallerie Apex and sends it to the factory. The
lead time varies from one month to two months depending on the situation and nature of
the product. If the required products are available in the CDC or factory, the products
are sent within a very short time. In order to digitize its process through electronic
medium, Apex Adelchi Footwear is going to start internal online ordering system within a
few days.
Distribution System
Apex Adelchi Footwear distributes its products to Gallerie Apex by using own distribution
channels with in the Dhaka City. For distributing its products outside the Dhaka City it
uses Courier services or rented truck. Its products come to CDC from the factory, and
then they are delivered to Gallerie Apex from CDC.
Distribution strategy
Apex Adelchi Footwear follows selective and Intensive distribution.
Selective Distribution: When a new product is introduced in the market, it first appears
in the divisional outlet only.
Intensive Distribution: If the new product best fits with the customer demand and if the
sales growth of the new product is high enough in the divisional outlets, then Apex
decides to go for intensive distribution. It then makes the product available in all the
Gallerie Apex.
Value Creation Stages in the Supply Chain
When marketing to local consumers, a 2 level Marketing Channel is maintained. In the
primary stage, value creation begins with new product development, which creates
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design and specifications for the product. Marketing and Sales generate demand by
publicizing the customer priorities that the product will satisfy. Marketing and Sales also
brings customer input back to new product development. Using these new product
specifications, the manufacturing unit transforms inputs to outputs to create the product.
On the first level, the Central Distribution Center delivers the product to various sales
centers (Gallerie Apex) to make the product available to the customers.
Gallerie Apex then displays the product and sells it to the customers. It also provides
after sales services.
4.6 EXPORTS
Apex Adelchi Footwear started exporting in 2000. Below is the list of the major countries
where Apex Adelchi Footwear Bangladesh Ltd exports its products.
Japan
Germany
Italy
France
Austria
Scandinavian region and Switzerland
Other EU countries
USA
Canada
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In the year 2008, Apex Adelchi Footwear Bangladesh Ltd exported shoes worth Bdt. 5.07
billion (Choudhury, 2010). The export of Apex Adelchi Footwear Bangladesh Ltd got a
new dimension after the affiliation with the Italian footwear producer La Nuova Adelchi
Footwear. The primary joint venture capital provided by La Nuova Adelchi Footwear was
Bdt. 150 million. So, it is evident that the capital contribution was not that significant.
But the main benefit of the affiliation was that Apex Adelchi Footwear Bangladesh Ltd got
recognition in the European countries and its export has boosted since then. Apex
Adelchi Footwear Bangladesh Ltd now designs its products using Italian product
development & technology. At the very first year of operation (after the affiliation), the
annual export was expected to be Bdt. 900 million and later on Bdt. 2 billion. Currently,
Apex Adelchi Footwear Bangladesh Ltd is responsible for exporting almost two-third of
the countrys whole footwear export.
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country, which makes it the second largest shoe retail chain after Bata. Its market share
is growing fast along with the emerging middle income population of the country.
Bata and Apex Adelchi, two of the country's leading shoe manufacturers and retailers,
are set to intensify its battle for customers with both companies sharply increasing its
number of stores. Comparisons between them are shown below:
It plans to set up some 20 new retail It will set up 40 different stores this year 10 city
outlets
It aims to cater to the footwear needs It caters to the demands of all income groups
of the middle class to upper middle
class in the urban and semi-urban
areas across the country
Its main objective is to provide It will focus on providing products within a price
customers enough choices in a fairly range that is affordable for different types of
narrow price range.
Its strategy is sustainable growth Its strategy is rapid expansion through delivering
through
delivering
high
standards
It wants to set up some complete Its biggest focus now is on the city and super
family stores enabling its customers to stores
have a pleasant shopping experience
(in 1000s)
(in 1000s)
Revenue
5992.5
5273.2
Gross Profit
719.1
1821.6
Gross Margin
12%
35%
Net Profit
247.3
476
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Net Margin
4%
9%
ROE
32%
53%
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5. ARBANA
When it comes to making Products, they make handmade shoes which are made out of
100% leather. Moreover, as mentioned earlier, their shoes are contemporary and
fashionable. They basically make Footwear for both Men and Women. Apart from
producing shoes, Arbana also makes Belt, Office Bag, Womens Bag, Money bag and Key
ring.
the
best
for
their
customers.
They
use
generations
of
accumulated
craftsmanship, combined with todays modern techniques to create individual shoes with
an exclusive "Arbana" personality. That is why they term themselves as Footwear
Thinkers.
5.2 SUPPLIES
Arbana buys the small components for shoes like insole, cushion material, buckles,
outsole and other tools and materials like glue, sturdy threads and cutting tools from
Puran Dhaka. The suppliers of that region normally charge lower prices for these raw
materials which is cost effective for Arbana.
5.3 MANUFACTURING
They have their own manufacturing department and tannery in Hajaribagh, Puran
Dhaka. They say it cost them more if they buy tannery from suppliers. So they set up
their own tannery to save cost and moreover this backward integration has also made it
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All the shoes in the manufacturing department are handmade, as mentioned earlier.
Thus, the process is labor intensive. Bangladesh being a developing country has
abundant cheap labor supply which is a major contribution for Arbana, mentioned one of
the employees of the company.
The footwear industry of Bangladesh has been traditionally being dominated by Bata in
almost all customer segments, as the market leader; while organizations like Apex as the
market challenger, and Bay Emporium, Jennys, Zeils and Leatherex as market followers
are continuously fighting to retain and increase their existing market share. All of them
have significant export revenue to back up their reputation and local sales. They have
their unique and strong supply and value addition chain. Also, there are lots of other
local manufacturers who are operating the market not only as suppliers of the big
brands, but also with their small-medium and meager number of outlets. Therefore, the
footwear industry of Bangladesh is quite competitive; and successful emergence of a
new player in this field is surely going to be challenging.
Arbana emerged in this saturated competition on May 8, 2011 with their mission is to
Develop new footwear architecture in Bangladesh. Founded by Mr. Mahim Rashid, an
architect of refined taste, the Arbana staffs proudly introduces themselves as the
Footwear Thinkers. Arbana is a local brand with global attitude. Besides operating in
the local market, it exports to a few countries like Dubai, Malaysia and Italy. Its
customers are modern men and women of the medium and upper income class who
enjoy underlining their personality with a contemporary look that combines freshness,
spontaneity and youthfulness. They make footwear for both Men and Women. Apart from
producing shoes, Arbana also makes Belt, Office Bag, Woman Bag, Money bag and Key
ring. The company boasts about its footwear which is 100% leather made and they
exhibit the traditional line of hand-crafted footwear. This gives the customers a sense of
superior quality and artistic sophistication. This feature has been very effective as
Arbanas point of difference for competitive advantage. People who purchase the
products of Arbana get an antique feeling of class. This makes them consider Arbana
product to be worth the money spent and repeat purchase. Therefore, keeping the
supply wheel rotating and maintaining the quality are what keep Arbana is business.
Although Arbana hasnt yet been able to capture enough market shares to significantly
challenge the likes of Bata, Apex or Bay, it has successfully achieved a good number of
loyal customers with its unique design, promised comfort and quality. The aristocracy
and uniqueness of the footwear design has the point of parity for Arbana from the very
beginning. All the designs are the creation of the Managing Director Mr. Mahim Rashid,
who himself is an architect and renders the footwear with artistic touch and at the same
time trendy as the go.
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Fortuna footwears mission is to provide the optimal blend in style, quality, and
affordability in footwear and accessories. The company sells shoes, leather bags,
etc, in its 20 or so retail outlets around Bangladesh. It also exports to countries in
European Union and United States. It has a cutting edge web portal installed by
Infrablue Technology. an award winning IT division of Fortuna group that started
in 2008.
6.2 SUPPLIES
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Fortuna has its own tannery unit which sells to both its footwear unit and other
clients. Ruma Leather Industries Ltd was bought in 1991 by the Fortuna group as
a strategic unit. The tannery is located in Hazaribagh on a three quarter acre plot
of land. It has state-of-the art equipment in its tannery with a capacity of
producing 500,000 square feet of finished leather per month. Ruma is targeted to
reach $12 million in exports, annually, by leveraging its experience technicians
and management team.
Other materials are sourced from China, India and Taiwan.
6.3 MANUFACTURING
Fortuna Park is the manufacturing department of Fortuna shoes. It is located in
Kunia, Gazipur and was set up in 2010. The manufacturing plant, which required
an initial investment of Tk 56 crore to set up, has a capacity to produce around
6000 pairs of shoes and 500 bags per There are four lasting lines - the 40,000
square feet factory in unit 1 and 30,000 square feet in unit 2. The factory
produces footwear products mainly for the international market, but also
manufactures shoes and accessories for the domestic market.
Fortuna also has its own shoe moulding factory. The moulding factory sources
plastic from China and India, and ensures the shoes are perfectly shaped.
6.4 EXPORTS
Fortuna closed down its garments unit in 2009. By opening Fortuna Park the next
year in 2010 and establishing Bangladeshs first shoe mould manufacturing
factory, Fortuna entered the international footwear industry. It started with the
aim to earn around Tk 200 crore in foreign currency a year. The reason Fortuna
closed down its garments manufacturing plant in 2009, was because of the
anticipated growth in the shoe and leather industry. Even though the demand for
fashionable and high quality leather shoes had declined in the international
market due to the recession at the time, there was still an opportunity to
leverage the demand for simple but necessary shoe products. At the time, shoe
industry was in the early stages that is similar to the early days of the
readymade garment industry. The CEO Fayaz Taher, marked this opportunity and
Page | 40
Bangladesh.
As Chinas labor cost is increasing, foreign buyers are looking for other places
where they can outsource their manufacturing department. Countries like China
and India are unable to produce high quality leather shoes at a low-cost. Foreign
buyers are nowadays seen shifting their manufacturing strategy and locally
producing the shoes. This gives Bangladesh the potential to meet the demand of
foreign buyers. With its own leather manufacturing department, Ruma Leather
Industries Ltd, Fortuna is vertically integrated and is able to enjoy a competitive
edge in sourcing its supplies. The company also partners up with foreign
companies. For instance, it had teamed up with a chinese company to establish
the countrys first shoe mould factory. This sets Fortuna apart from other
footwear companies, most of which uses wooden moulds that are not as
accurate. In addition, the company is in a joint venture with a Spanish company
to make outsoles. It collects over 100 different outsole styles from Spanish
sources. Fortuna also has state-of-the art management team, and undertakes
public relation move to promote its factory compliance, environmental standards
and ethical work culture. Buyers usually inspect Fortunas plant facilities and
retail outlets before placing order on the company.
Fortuna has worked with foreign companies like H&M, Melillo and Anto Harness. It
makes ballerina shoes, boots, sandals, etc for ladies, men and children to meet
the orders set by its foreign buyers.
Womens Shoes: Fortuna produces heels and flats for women. Most of these
footwear are made of leather and are have a fusion of both local and foreign
designs. Its prices range from around 600 Tk to around 3000 Tk for womens
footwear in the local markets.
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Mens Shoes: Fortuna has a wider range of mens shoes than womens. It sells
converse, sandals, shoes, EVA sandals, etc, for men. It terms its mens shoes as
intelligent, confident, stylish, creative, relaxed, driven, modern and out of the
box. Shoes for men has a higher average cost with minimum price starting from
around
Kids Shoes: Alongside selling women and mens designs, Fortuna also
specializes in producing kids shoes. Kids shoes range from lightweight to
medium weight to provide extra support for the kids.
Other Items: Fortuna also sells bags, wallets and other leather accessories.
in
Bangladesh. Fortuna also aims to have an online presence and uses third party
B2B websites like Alibaba to showcase its products to foreign buyers.
Even though the recession hit the countries in the west quite hard, there is a
demand for day-to-day footwear at an affordable price. This is where
Bangladeshs capabilities comes in and Mr Fayaz hopes to leverage these
opportunities to help Fortuna move forward. We want to continuously improve,
he believes. His young team who has been with the footwear unit since its
inception, are a mixture of young, ambitious and capable employees who share
the same vision as their boss.
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Mr Fayaz has also set quantifiable goals for its footwear unit. He believes that
Fortuna will reach China standard some day. Currently China makes 400-500
pairs of ballerina shoes per hour, whereas Fortuna makes 250-275 per hour. The
target is to make 300-325 ballerina shoes per hour by the end of this year, and
keep increasing its capabilities in the years to come.
Apart from Fortunas advantage of being a large conglomerate with an
established brand name, Mr Fayaz believes that its young team is the biggest
asset of the company. Nashad Moyukh, who is the assistant factory manager of
Fortunas footwear unit, joined in 2010 right after graduating in engineering from
University of Dhaka. With on-the-job-training from his seniors, Mr Nashad now
believes that he has become fully capable of handling the factory work. He
boasts Fortunas fully compliant factory which foreign buyers always inspect
before placing orders at Fortuna. Altogether, Mr Nashad envisions that Fortuna
will be able to get to the next level by increasing its plant capacity and
productivity.
Fortuna also maintains its business by employing the values of Total Quality
Management. As Ashraful Alam, the quality manager of Fortuna explains, the
company follows all the requirements of the foreign buyers and has state of the
art lab facilities for its moulding unit in the factory. Shoes are checked at every
level and a final inspection is done to make sure the end-product meets all the
requirements of the buyer. Furthermore, Ashiq Iqbal, head of planning, explains
how Fortunas customized excel sheet helps to maintain good production flow in
the factory. There are plans to build a cloud system so that the work can go
digital and communication is enhanced. This will help to monitor and share
planning reports, production reports as everything will come under one platform.
Consequently, deadlines can be met more smoothly when such digitization has
been installed.
With his entrepreneurial vision and the passion and commitment of the young team, Mr
Fayaz Taher strongly believes in taking Fortuna, and ultimately Bangladeshs footwear
industry to a higher level through continuous improvement and forward thinking. Its
advanced factory facilities, public relations and brand name, are only some of the tools
and Mr Fayaz believes in leveraging his young team to achieve the ambitious vision.
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7. LEATHEREX
Leatherex Footwear Industries Limited, which is 100% leather based Footwear Company,
is registered in Bangladesh as an SME. It has been working continuously with inherited
expertise and know-how. It is now a leading footwear manufacturer in Bangladesh,
catering to the footwear needs of a global clientele alongside local demand. It
manufactures and exports all kinds of Leather Footwear and footwear components.
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Founded in March 2000, Leatherex has utilized most modern state-of-the-art machinery
for production of footwear. All its manufacturing operations include both automated and
manual components. This permits a yearly production of up to 800,000 pairs of shoes
and sandals. Leatherex is operated under technical collaboration with Japan, Italy and
Taiwan. The main advisor for Leatherex Footwear Industry Limited is Japanese and
because of good relationships, most exports are made to Japan and a lot of assistance is
also obtained from Japan. Its main products are leather casual, basic and formal shoes,
mesh shoes, pumps, men's and ladies sandal and boots.
Working Experience of a decade in the field of leather chemicals, processing of raw-hides
to finished leather, producing shoe upper to footwear, all contributed to shape the
company to what it is today.
Leatherex Footwear Industries Limited has been awarded as one of the top 16
companies in Bangladesh in 2010. It has also won numerous other awards and accolades
over the years in lieu of its excellence, including D&B Corporate Award 2010, The
Financial Mirror Business Award 2005, and National Export Trophies for the years 200809, 2005-06 and 2001-02.
Leatherex Footwear Industries Limited is associated with five other companies, namely
Impex International
Impex, founded in 1999 is an expert and experienced in handling leather sector for more
than a decade. Impex International is a buying agent on behalf of many world famous
companies; Sannyo Leather Co. Ltd., Himeji, Japan being one of them.
Catalyst Polymer
Catalyst Polymer Industries Limited is a 100% export shoe component manufacturing
industry in Bangladesh. Founded in 2001, it is now manufacturing following Shoe
components :
TPR Sole
Mid Sole
Heel
Lift
Different Wedges
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The technology of Catalyst is adopted from Japan, Italy and Taiwan. Catalyst exports for
the footwear of Europe, Japan and Korea. Catalyst imports raw materials from reputed
suppliers globally. Catalyst has its own design development and processing lab (R&D), it
can develop products according to the design of the buyers, new ideas, new creations,
new inventions to the reality.
Nazmul Food Ltd.
It is a sister concern of Leatherex Footwear Industries Limited.
Scarpe e Moda Ltd.
An Italy-Bangladesh joint-venture leather footwear manufacturer, Scarpe e Moda Ltd.
operates under Italian technical know-how and to produce hi-tech and top Italian brands
in Bangladesh, those of which are sold in Europe, USA and Australia. The company has
started its commercial production from 2nd May, 2011. Scarpe e Moda Ltd. is the sister
concern of Leatherex Footwear Industries Limited.
In order to gain a better understanding of Leatherex, we must look at six components
that make up a footwear industry - suppliers, distributors, manufacturing, designs,
exporting and retailing.
7.2 SUPPLIES
Leather
Leather is one of the main, and most important component of a footwear product for
Leatherex. Leather for shoes and sandals is obtained from:
1.
made in the Hazaribagh district. Leatherex also obtains nearly all of its leather for
processing into footwear from one of the 200 tanning factories in Hazaribagh district.
2.
Leatherex, owned by the same owner Mr. Nzamil Hassan. It is engaged in the
manufacturing and exports of Crust, Lining and Finished leather of Cow, Goat and sheep
in Bangladesh.
processed leather.
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3.
Lastly, if the demand for leather is still not met then Leatherex imports from India,
Pakistan or Italy.
Outsole
The outsole is the layer in direct contact with the ground. Dress shoes often have leather
or resin rubber outsoles; casual or work-oriented shoes have outsoles made of natural
rubber or a synthetic material like polyurethane. The outsole may comprise a single
piece, or may be an assembly of separate pieces, often of different materials. On some
shoes, the heel of the sole has a rubber plate for durability and traction, while the front
is leather for style. Outsole is obtained from:
1.
2.
outsoles, TRP soles, mid soles, heels and other components of the outsole. This is used
by Leatherex in the manufacture of their footwear.
Insole
The insole is the interior bottom of a shoe, which sits directly beneath the foot under the
footbed (also known as sock liner). The purpose of insole is to attach to the lasting
margin of the upper, which is wrapped around the last during the closing of the shoe
during the lasting operation. Insoles are usually made of cellulosic paper board or
synthetic non woven insole board. Insole is obtained from:
1.
With the use of imported shank boards and sheets, Leatherex manufactures their
Korea or Taiwan.
Molds
Molds for shoes and sandals are imported from Taiwan, Japan and Korea.
Other required materials such as Glue/Adhesive, Zippers/Buckles, Primer, Chemicals,
Synthetic Linings, Cotton Linings, Toe Puff, Different Sheets may be locally sourced or
imported. The packing inner box, master carton and silica gels, and wrapping paper are
also locally sourced and imported.
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The company has a Supervisory Bond License and imports of all of its raw materials duty
free covering GSP regulation.
7.3 MANUFACTURING
Leatherex Footwear has a factory facility of 75,000 square feet with 1200 employees, 3
assembly lines and a capacity utilization of 60-70%. Currently it can produce up to
800,000 units per year depending on the design and article, but the expansion of
production and production capacity is possible. Production facility components comprise
of insole and components, cutting section, sewing section, lasting section, outsole
section - leather, jute or plastic, TRP sections, finishing section and finally packing
section.
7.4 DISTRIBUTION
Leatherex is mainly export oriented; they take orders from buying agents and marketing
companies working for large overseas clients such as Japan, UAE, USA and European
Union. The buying agents represent these clients and price negotiations, negotiations of
payment, terms and conditions are all done through them. In order to be certain that the
factory is compliant with rules and regulations, these buying agents also make regular
visits on behalf of their clients. Furthermore, the agents are responsible for product
inspection and supervision of packing and container stuffing to ensure that the footwear
does not get damaged during shipment.
Leatherex has also recently opened a retail outlet for the domestic consumer market
where they sell their products directly to the consumers. There are no intermediaries and
a 0-level supply chain is followed.
7.5 EXPORTS
As previously mentioned, Leatherex is more export focused. The owner Mr. Nazmul
Hassan is vastly experienced in international leather products training and because of his
good trade relations is able to export to Japan, Korea, USA, UAE, Germany and Italy.
Leatherex is well equipped as per GSP regulations and KPT (for Korean market) for duty
free access and duty free raw materials import. An Annual revenue of 35 million USD is
made from exports only. The main exporting companies are B.Z. Moda by Everybody,
Italy, Regal, Alfredo Bannister In, ITO-Yokado and Fitfit.
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Page | 50
Leatherex has launched international brands of leather shoes and bags and Italian
famous brand Garden Franco Ballin and Tu Ogi. Now customers residing here can enjoy
world class foreign shopping at home.
Leatherex also offers both the in-store and online shopping. To shop online, a customer
needs to simply choose his/her design from the official facebook page. Their product
number, price including VAT and product description and then need to contact any
helpline to book an order can be seen with the picture. To make shopping experience
more convenient, they also offer home delivery services. Considering their huge
inventory with finely tuned categories and their variations, Leatherex is the shoe store
worth checking out.
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shoes require a different approach for producing than does the manufacturing of finished
leather.
This dilemma lead Mr. Hassan to establish a new company, in 2001, which
specialized in the manufacturing of soles of different kind aptly named Catalyst Polymer
Industries Ltd. This move further strengthened the value chain for Leatherex giving it
further competitive advantage.
Leatherex, although a bit late in the game, is following the footsteps of Apex Adelchi and
Bay Emporium and making use of their production capacities and marketing to the
domestic market.
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It is currently one of the major shoe retailing companies. The brand is getting popular
very fast. It has 42 retail stores nationwide set at different strategic locations. The brand
is famous for leather shoes & leather sandals.
Bays mission is to satisfy customers by providing commercial fashion footwear at
superior value and quality served by competence sales associates. Its vision is to
position Bay Emporium as one of the leading marketers of family footwear for medium to
medium high income group of customers in Bangladesh.
Since Bay Footwear Ltd has been established, it has kept the cooperation reciprocal
benefit management conception. Bay Footwear makes efforts to seek customers,
suppliers and utilizes growth together to anticipate the mutual assisting and cooperation
and create benefit. This also is the origin of their company name Bay Footwear which
emphasized Three Wins management conception.
8.2 SUPPLIES
Bay collect their product from its own processing factories. Its first production factory,
Unit-1, which was established in 2001, is conveniently located near Dhaka in Konabari,
Gazipur. At that time, Bay Footwear Company still focused on vlcanized shoe, sold mainly
in Europe & East Asia. Bay Footwear second factory that means Unit-2 in Mouchak,
Konabari was set up in 2007, and started to produce cold cemented shoes. In 2008,
Unit-2 introduced Goodyear Welted construction and the stitch down technology from
Europe and started to produce special structured shoes. In order to manage the main
materials, Bay Footwear engaged in vertical integration and established the material in
factories to coordinate the demands of the production line expansion and to actively
control production costs, reduce material lead time and master the production cycles.
8.3 MANUFACTURING
Bay Footwear Ltd has two production factories in Konabari & Gazipur which are capable
of producing vulcanized, cemented, Goodyear Welted, stitch-down, safety shoes and
other construction shoes. The maximum capacity exceeds 5,000 pairs per day. Following
along with the improved production quality, the production system regulation conformity,
as well as the research and development designed capacity enhancement. Bay do not
have any training program of their own, thats why they only recruit trained employees
Page | 54
with higher salaries. At present Bay has got around 850 employees working in different
branches.
8.4 DISTRIBUTION
Bay focuses only on customers and distributes products accordingly. It uses a one-level
consumer marketing channel. It has Tannery factory at Hazaribagh and processing
factory at Konabari acting as Manufacturers, and the Bay emporium retail shops situated
nationwide sells only to the final consumers. At present Bay Emporium have 42 branches
established around the nation and sells around five thousands pairs of shoes every year.
8.5 EXPORTS
Bay used to supply to different countries including Hong Kong, Italy, France, Japan and
UAE. But it decided to terminate its export due to high increase of local demand but
relatively lower increase in production rate. So at present Bay sells only in the domestic
market.
9.
The report has evaluated the business models of six footwear companies - Bata, Apex,
Arbana, Fortuna, Leatherex and Bay Emporium.
footwear organization whereas Arbana is the most recent. All these companies differ
from the others, in one way or the other. Their differences reveal some key dynamics of
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the footwear industry especially when they are compared in terms of their suppliers,
manufacturing department, distribution methods, exports scenario, product offerings and
retail outlets. Each of these factors is considered separately, and the major factors are
emphasized.
Supplies Large companies like Bata and Apex, tend to procure their raw
materials from independent suppliers. While Bata sources part of its raw materials
from independent suppliers at Hazaribagh, Apexs production depends entirely on
them. These companies employ transactional exchange relationship with their
suppliers, which are marked by short-term contracts with little repercussions.
Smaller scale companies, and more export orient ones like Fortuna and Leatherex
have backward linkage and source raw materials from sister concerns of the
company. Due to the low bargaining power enjoyed by smaller counter parts,
companies like Arbana are forced to have their own tanneries in Hazaribag. Other
items like insoles, cushion material, buckles, outsole and other tools and
materials like glue, sturdy threads and cutting tools, are usually sourced from
China, India and Taiwan. These raw materials are available in Puran Dhaka, but
companies willing to maintain high quality, source it directly via B2B contracts.
Manufacturing All of the companies covered in this report, manufacture their
own branded footwear. However, Bata, Apex and Leatherex, import premium
shoes from places like Italy, India, and Thailand. With a import duty of around
101%, too much import affects the profitability of the companies but low price
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Hence, the above comparison gives a comprehensive view of the dynamics of the
footwear industry in Bangladesh. For instance, it can be inferred from this analysis, that
large companies like Bata and Apex tend to have a higher bargaining power when it
comes to dealing with suppliers; hence, are able to employ transactional exchange with
the independent suppliers. Much less established and newer companies like Fortuna, Bay
Emporium, Arbana and Leatherex cannot enjoy such advantage and are compelled to
vertically link their source of raw materials. This gives them a more comprehensive value
chain formation, and it is not surprising that the latter group is able to offer more
differentiated and high quality footwear products, which are mostly leather based, albeit
at a higher price. Furthermore, as Bata and the follower Apex leads on the local footwear
industry of Bangladesh, newer ventures with their ambition and creativity, are tapping a
more fashion-conscious market whose consumers are ready to pay at a premium to
acquire stylish leather footwear manufactured locally.
Hazaribagh
nation for
its serious
environmental effects. But it also plays an unparalleled role in the growth of the leather
industries of our country. The location acts as central hub of all the tanneries from which
processed materials are delivered to different footwear industries situated nationwide.
About 30,000 people work in the tanneries, producing leather for shoes. Ninety percent
of Bangladesh's shoe leather is made in the Hazaribagh district (Kogure, 2013). So the
location has significant influence over the development of the footwear industry.
Importance of Hazaribagh in the Footwear industry
Hazaribagh holds the key to the flourishing of the footwear industry, because of its Locational Concentration
Historically, the tannery industry got concentrated in the Hazaribagh area of Dhaka city
where nearly 90% of all tanneries are located. A number of tanneries took the
opportunity in 1990s for the production of crust and finished leather. There are
reportedly around 220 tanneries in Bangladesh but, in fact, only 113 tanneries are in
effective operation, out of these 20 units are reported to be fairly large (7 units very
large), around 45 units are considered of medium size and around 48 units are
considered small groups. With the exception of ten tanneries located in Chittagong (and
a few in other cities) the leather tanning industry is concentrated at Hazaribagh area in
Dhaka (Biswas & Hamada, 2012)..According to estimates, almost 90 percent of the
countrys leather and leather goods come from Hazaribagh, suggesting the significance
of the location.(Ahmed & Bakht, 2010).
Synchronized Developmental Trait
The development of tanneries in Hazaribagh can have profound impact in the
development of footwear industry. Among the three sub-sectors of the leather sector, the
tanning industry is the most important and fundamental of all. There are more than 200
tanneries while the majorities are concentrated in the Hazaribagh area of Dhaka. More
than 400 million square feet of raw hides and skins are processed and exported by
tanneries each year in recent times. This sub-sector earned revenues in excess of USD
330.16 million during 2011-12 with a growth rate of more than 10 percent. The
importance of this sub-sector is grounded on the regular and abundant supply of raw
materials from the local livestock base. Additionally, the significance of this sub-sector
also stands on the fact that it holds key to the enormous growth potential of other two
sub-sectors. It is evident from research that the sector loses massive value addition
opportunities in exports as 50% of leather is being exported as lower value-added
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products in the form of semi-finished and finished leather. Even though the other 50% is
being converted into footwear and leather products, most of the exports are targeted
towards low-end market. These findings indicate that the planned development of the
tanning industry could help entrepreneurs of other leather sub-sectors like footwear
indutry to tap bigger export potentials.
Economies of Scale
The footwear companies are reaping the facilities of economies of scale due to high
concentration of tanneries in Hazaribagh. The established brands like Bata and Bay
Emporium have their own shoe processing factories at Hazaribagh. The factories enjoy
positional advantage as they can collect raw materials and components at a lower price
than the factories located elsewhere. This diminishes the production cost of the
companies and allows them to deliver products in the market at a lower price. Besides,
the centralization of the processing factories encourages mobility of labor force within
the firms, leading to quality product design.
Environmental Trade-offs
The contribution of Hazaribagh in the growth of footwear industry is undeniable. But the
terrible environmental condition of the place begs the question whether the revenue
earned from the sector should be addressed as blood money. There is no waste
management system at Hazaribagh. Dozens of chemical materialsincluding chrome and
sulfur compoundsare used to process the leather. The chemicals create a foul-smelling
stench that hangs in the air of the Hazaribagh district. Despite the use of hazardous
materials, most workers in the tanneries do not wear gloves or masks. A survey
conducted in 1999 on 179 workers at tanning factories by the Society for Environment
and Human Development, a nongovernmental organization, found high levels of disease.
The incidence rate of dermatitis among the tannery workers was 52 times that of the
national average, and the rates for gastritis and asthma, respectively, were 37 times and
six times the national average. The poor waste management has also contributed to the
deterioration of water quality of Buriganga (Paul et al., 2013).
The factories and tanneries require installing modern technologies in their production
and waste management systems. But the production cost will go up then and it may turn
to be a big constrain for Bangladesh to compete with others in the global market. So it
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can be assumed a trade-off relation between the export trend of leather sector and the
water quality of Buriganga.
3. Distributors:
a. Do you market to consumers or industries or both?
b. What type of supply chain do you follow?
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6. Exporting:
a. Do you export?
b. Do you export shoes designed by yourselves or do you act as only a
manufacturing facility for foreign designed products?
c. Where do you export?
d.
j.
7. Retail:
a. How many retail outlets do you have? Since when are they
operating?
b. Where are they?
c. How is the local demand pattern (design, frequency of purchase,
reservation price) compared to international?
d. How does Eid and other festivals affect demand?
e. How does local non-brand retailers located in cluster on and near
Elephant Road affect your business?
f.
g. Who are you main market competitors? (Cats Eye, Artisti, Mustafa
Mart VS Apex) [Different industry same market] [Please note that
Cats Eye and Artisti outsource their manufacturing and designing
to Thailand for shoes. Ato boro gadha -_- ]
h. What would you say your current local market share is like?
i.
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Ahmed, N., & Bakht, Z. (2010). Leather Footwear Industry in Dhaka: A Case Study.
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