INTRODUCTION:
The term ‘apparel’ or ‘garment’ would include ready-made garments also as
knitwear/hosiery. The apparel industry is classified as those establishments
which cut and/ or stitch/ structure garments out of woven or knitted fabrics
without being involved within the manufacture of materials .
All these garments are often broadly classified into 3 categories. Formals,
Casuals and Designers. Formal range of garments refers of these dresses, which
are worn at offices and other sober places of visit. Casual garments ask
that breed of dresses whose styles are generally nonconformist with normal
features of over sized pockets, pockets with flaps, larger front buttons, loose fit
etc. Designer garments ask the road of dresses which are worn at parties,
joyous gathering like weddings, receptions where general code of dress
is not specified and has limited editions of a sampling cater to little segment,
Denim garments come under the category of semi-formal wear.
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Levi’s Strauss made the primary pair of jeans using tent canvas to assist miners
stash away enough gold into various pockets of hurriedly sewn up trousers,
during the gold rush in California in1890’s. Today every person ,
man or women wear jeans. Comfort is the key word, which has contributed
to a boom within the acceptability of jeans as a part of lifestyle such a lot so, that it
has nearly come to be accepted as an executive, formal wear too. Denim has
become so popular among the people that a Tamil Film maker has named a movie
as “Jeans”, starring former Miss world, Aishwarya Rai.
Denim dresses over the years have revealed a capability to transcend age
and gender barriers. Boys and girls, men and women, the young and therefore the old have
come to carry the view this comfort and fashion. Travelling during a pair of jeans and
T-shirt or sports-neck shirt is that the definition of “travelling comfortably
dressed”. The denim fabric, accessories and trims like collars, zips, buttons, sewing
thread, fusible/non fusible linings etc. technology and therefore the skilled workers for
making these garments are available in India at competitive prices. aside from
the availability of staple , various support services like garment dyeing/
bleaching/finishing units, packing
material manufacturers etc. are also available within India.
MARKET POTENTIAL:
The state of Maharashtra is one among the leading manufacturers’ of readymade
garments for domestic and export markets within the country thanks to its natural
advantage of peaceful industrial climate, high skills of labor force, easy availability
of raw materials, reliable infrastructure facilities, uninterrupted power supply etc.
In the domestic market readymade garment industry has made spectacular
progress within the last decade in our country thanks to vast bourgeoisie
population which is equivalent in numbers to the entire population of USA
and has 17 per cent of the world’s population. Readymade garment
business thrives during a situation of rising levels of incomes particularly of the
middle and upper middle classes. At the same time export markets for
readymade garments are very large and the growth is tremendous. As per AEPC
report, overall share of Indian garments in the International market as just 2.4%
when compared to other smaller nations like South Korea , Hong Kong, Malaysia,
Bangladesh, Sri Lanka, where it's more than 4% each. As per WTO agreement
all quota restrictions for exports are going to be removed by 2005 AD which can further
boost the exports from country. In Indian denim market, there's a
premium segment which is catered mainly by foreign brands like Wrangler,
Pepe, Lee’s and Levi’s (all are American). However, this premium segment
accounts for a mere 3 percent, in volumes terms, of the entire jeans
market, pegged at approximately 25 million pairs once a year . the quality
and economy segments catered by Indian brands like Flying Machine, killer,
Texas, Sunnex, New Port (Aravind Mills), Trigger (KG Denim), Ruf and Tuf (tailor
jeans by Aravind Mills occupy remainder of the market). the entire jeans market in
India is estimated at about Rs. 2855 crores during which the premium segment
accounts for Rs. 275 crores to 300 crores, standard segment of around Rs.
840 crores, and therefore the rest by the unorganized economy segment. Predictably, the
economy segment enjoys the most important market share by volume-nearly-70 per
cent. there's fast growing trend within the standard and economy segments than
the premium segment. The semi formal segment is growing at a rate of 35
percent once a year for the previous couple of years, and will still grow at this rate.
There is a growing trend towards soft jeans made with cellulose rayon and
Tencel blended denim garments. BASIS AND PRESUMPTIONS
1. The project profile has been prepared on the idea of single shift of 8 hours every day ,
25 days in a month and at 75% efficiency.
2. It's presumed that within the 1st year the capacity utilization are going to be
70 % followed by 85% within the next year and 100% within the subsequent
years.
3. The rates quoted in respect of salaries and wages for skilled workers et al. are the
minimum rates within the state/ neighboring states.
4. rate of interest for fixed and dealing capital has been taken @14% on
an average, whether financed by bankers or by financial corporations.
5. Margin money required is minimum 30% of the projected investment.
6. Pay Back period of the Project: After the initial gestation
of one and a half years, it will require 5 years to pay back the
loans.
7. The rental value of the work shed and other built up/covered area
has been taken at the speed of Rs. 20 per square meter .
8. The rates quoted in respect of machines, equipment and raw
materials are those prevailing at the time of preparation of this
project profile, and are likely to vary from supplier to supplier and
place to put . When a tailor made project profile is ready
necessary changes are to be made.
9. capital for 3 months has been taken into consideration for smooth running
of the project.
IMPLEMENTATION SCHEDULE
Sl.No. Activity Period
1. Preparation of the Project Report: (a) Calling quotations 1 month
(b) Preparation 2 weeks
2. Provisional Registration 1 week as SSI
3. Financial arrangements 3 months
4. Purchase and a couple of months procurement of machinery
5. Installation of machine 1 month
6. Electrification 1 month
7. Recruitment of staff and 1 month workers.
TECHNICAL ASPECTS
Process of Manufacture Manufacture of denim garments is like
any other garment except that these garments require special care and
finishes. the essential outline of the operations for denim garments in
general is given below.
1. Pattern design and pattern making.
2. Cloth cutting by mechanical process.
3. Sewing by high-speed industrial sewing machine.
4. Trimming and inspection.
5. Ironing and pressing as finishing process. Designers use five elements to make
a design which will stimulate the potential consumer to shop for like colour, silhouette,
drape, texture and tone. Besides these the designer selects buttons, uppers,
snaps, thread lace, tapes, braids, medallions, sequins and a spread of ornaments and
closures and ornamental devices to impart the specified design effect.
Cutting involves three basic operations, i.e. making the marker,
spreading the material and chopping fabric into the marked sections. There
are six sorts of machines available to chop or cut a lam into the component
parts of the market like rotary blade machine, vertical reciprocal blade
machines, band knives, almost like band– saws, die clickers systems with straight
blades and automatic computerized laser beam cutting machines.
The sewing operation is performed to join the individual cut components in
to desired shape by using power operated home appliance .
Fusing and cementing are processes for stitching or decorative seaming. In
fusing, the seam bond on decoration is formed by melting some fibre or finish
content within the material during a manner that joins the sections or decorates within the
desired area. In cementing, the bond or decoration is formed by an adhesive, such
as cement, glue on plastic which is applied to the materials during or
immediately preceding the cementing process. Fusing is either by direct heat,
by hot head fusing presses, in which pressure area is heated by
electric heating grade or steam. Cementing processes use mechanical
pressure systems with inbuilt head application counting on the adhesive
materials used. Moulding may be a process that changes
the surface character to photography of a garment of 1 of its stitch sections
by application of warmth , moisture or pressure. Pressing, pleating, blocking
mangling, steaming, creasing, curing and casting curing and casting are trade
terms for various moulding processes.
Pressing has two major divisions: Buck press may be a machine for pressing a
garment or section between two contoured, heated pressure surface that
may have steam vacuum systems in either or both surface.
In the field of casual fashion the fade look has significant value. Previously the
faded effect wont to come after repeated washing of the garment. Now we will
get the fade effects instantly by latest washing technology and it plays a really
important role within the sale ability of the denim garment.
There are many sorts of washes. The prominently used are Hard Wash, Half
Bleach, Full Bleach, Marble Bleach, Acid Wash, Stone Wash, Chemical Wash, Ice
Wash, Moon Wash, Bright Wash, Gun Wash, Camel Wash, Ink Wash etc.
Process-flow Diagram
Design Sample
↓
Fabric checking and layering
↓
Card board Pattern
↓
Cutting, segregation and bundling
↓
Stitching (single tailor or chain system)
↓
Trimming
↓
Thread cutting and labeling
↓
Quality control check
↓
Washing, drying and pressing
↓
Individual packing
↓
Carton packing
↓
Dispatching
Quality Control and Standards
In addition to various fabric defects like slubs, snarls, shade variations from
selvedge to selvedge especially with dark shades like red, turquoise, navy blue,
mustard, dark lilac, etc. and shade variation in several batches should be
checked before fabric is cut for stitching . It is very essential to take care of garment
industry, because the export markets are highly competitive. No quality
specifications are followed either BIS or by the other institution because the same can
not standardized thanks to frequent fashion changes within the apparel industry .
However, general quality practices like good house keeping periodic checks at
each and each stage of production should be practiced. to seek out out various
quality parameters like colour fastness, tearing strength, bursting strength,
shrinkage test etc. testing services offered by reputed laboratories like
ATIRA, BTRA, SITRA, NITRA, SGS India etc. shall be utilized to watch and record
the quality levels at regular intervals.
Production Capacity (per annum)
On average 10 pieces of adult
garments are often produced with one
machine in conjunction with the special
machinery that works as complimentary.
Production per machine per day = 7 pieces
of 8 hours
Production per 50 machines = 350 pieces
per day of 8 hours
Production per 50 machines = 8750 pieces
per day of 25 days
Annual Production Capacity = 1,05000
(a) Quantity : 1.05 Lakhs pieces
(b) Value : Rs. 285 Lakhs
Motive Power
A total of 45 kW or 60 HP power is required to run at full capacity and this
can be drawn from state electricity boards.
Pollution Control
Unit goes to try to to only cutting stitching, pressing operations for the
manufacture of readymade garments, which doesn't involve in discharge of
any sort of pollution. Hence there's no need of taking measures to regulate the
pollution.
Energy Conservation
Another important international aspect of the recent period is energy
conservation. The energy conservation will make the industries to scale back their
production costs and thereby stay more competitive within the market. This matter
should be the priority of each person involved within the day to day operations of
any industry. Idle running of varied machines, heaters, boilers, lights, fans,
air conditioners etc. should be completely avoided. Suitable capacitors
and energy saving devices should be incorporated whoever possible to
minimize the wastage of energy.
FINANCIAL ASPECTS
A. Fixed Capital
(i) Land and Building (Rented)
(a) Built up/Covered area 1000 sq. mt.
(b) Open/Uncovered area 200 sq. mt.
Total Area 1,200 sq.mtrs.
Average Rental Charges = Rs. 24,000
(per month) @ Rs. 20 sq.mt.
(ii) Machinery and Equipment's
Sl. Description No. Rate (approx.) Amount
No. (Rs.) (Rs.)
1. 8” Power cutting 1 65,000 65,000
2. 8” Hot drill 1 50,000 50,000
3. Band knife cutting 1 5,00,000 5,00,000
machine
4. Cloth clamps 15 1,000 15,000
5. End cutter (Straight) 2 50,000 1,00,000
6. Single Needle 50 10,000 5,00,000
Sewing Machine
7. Single needle 1 35,000 35,000
sewing
m/c with thread
trimmer
8. Single needle 1 35,000 35,000
sewing
m/c with edge
trimmer
9. Overlock with 4 35,000 1,40,000
softy stitch
10. Double needle 2 60,000 1,20,000
straight machine
11. Double needle 1 80,000 80,000
split needle
machine
12. Three needle 1 1,50,000 1,50,000
feed of the arm
machine
13. Double Needle 1 75,000 75,000
feed of the
arm machine
14. Twin needle 1 75,000 75,000
double chain
stitcher
15. Bar tacking 3 80,000 2,40,000
machine
16. 4 Needle double 1 1,30,000 1,30,000
chain stitch
machine
17. Snap fastening 1 1,70,000 1,70,000
machine
18. Button hole 1 1,10,000 1,10,000
machine
19. Button stitch 1 50,000 50,000
machine
20. Embroidery Single 1 1,50,000 1,50,000
thread Computerised
machine
21. Automatic Jeans 1 2,50,000 2,50,000
pocket sewer
22. Compact 1 3,00,000 3,00,000
computerised
embroidery
machine
23. Trouser Topper 1 3,50,000 3,50,000
24. Steam Iron 4 5,000 20,000
25. Vacuum tables 4 35,000 1,40,000
26. Steam generator 1 70,000 70,000
27. 50 kg washing 1 2,00,000 2,00,000
machine
28. Hydro extractor 1 70,000 70,000
29. Drying tumbler 1 1,00,000 1,00,000
30. Diesel Generating 1 1,00,000 1,00,000
set 20 kVA
31. Non-IBR Boiler 1 1,00,000 1,00,000
32. Mini Transport 1 2,50,000 2,50,000
Vehicle
33. Borewell with 1 1,00,000 1,00,000
5HP motor
Testing Instruments
1. Electronic Micro 1 10,000 10,000
balance
2. Fabric ends/picks 1 15,000 15,000
tester
3. Fabric thickness 1 25,000 25,000
tester
4. Shrinkage tester 1 40,000 40,000
5. Colour fastness to 1 15,000 15,000
washing
6. Fabric strength 1 40,000 40,000
tester
7. Crease recovery 1 55,000 55,000
tester
Total 52,80,000
(iii) Other Fixed Assets (Rs.)
1. Erection and installation charges 2,00,000
2. Electrification and wiring 1,00,000
3. Office furniture 1,00,000
4. Pre-operative expenses 1,00,000
Total 5,00,000
(i) Salaries and Wages
B. Working Capital (per month)
Sl. Designation Nos. Salary (approx.) Amount
No. (Rs.) (Rs.)
Administrative Staff
1. Marketing manager 1 60,000 60,000
2. Merchandisers 2 30,000 60,000
3. Store Keeper 1 25,000 25000
4. Accountant/Cashier 1 20,000 20,000
(Part time)
5. Clerks/Typists (Part time) 2 11,500 23,000
6. Peon 1 9,250 9250
7. Watchmen 2 9250 18,500
8. Driver 1 12,500 12,500
Production Staff
1. Technical Manager 1 70,000 70,000
2. Line Supervisors 4 18,500 74,000
3. Pattern/Cutting master 1 45,000 45,000
4. Fabric/garment 5 12,500 12,500
checkers
5. Skilled tailors 60 (on contract) 7,00,000
6. Fitter 1 9,000 9,000
7. Electrician 1 10,000 10,000
8. Helpers 4 9,000 36,000
Total 1'1850'50
Add perquisites @ 10%
(ii) Raw Materials
Sl. Description Qty. Rate Value
No. (Rs.) (Rs.)
1. Denim fabric in 15,000 120/ 1'800'000
different colours mtr.
(6 ozs. to 9 ozs. GSM)
2. Embellishments LS 15% 1,90,000
like collars, of the
Interlining fabric
cloth, (Rounded of)
zippers, sewing
thread, elastic,
labels, buttons etc.
Total 1'990'000
(iii) Utilities (Rs.)Approx.
Electricity bill, Water charges, Fuel, 60,000
coal and furnace oil
(iv) Other Contingent Expenses (Rs.)
1. Building rent 50,000
2. Repair and maintenance 10,000
3. Transportation and cartage 25,000
4. Postage and stationery 5,000
5. Telephone bills 6,000
6. Insurance 15,000
7. Sales and advertisement 80,000
8. Miscellaneous expenses 20,000
Total 2,11000
(v) Total Working Capital (per month) (Rs.)
1. Salaries and wages 1'185'050
2. Raw Materials 1'990'000
3. Utilities 60,000
4. Other expenses 2,11000
` Total 3'446'050
C. Total Capital Investment
1. Fixed Capital Rs. 57,80,000
2. Working capital (for 3 months) Rs. 10'338'150
Total 16'118'150
Tbc.