BUSINESS PLANFor Small Garment Manufacturing Firm TABLE OF CONTENTS S.NO 1 2 3 4 5 6 7 8 TOPIC Executive Summary Vision, Mission & Goal General Company Description Management Plan Board of director Organizational structure Marketing Strategy Organizational plan for Manufacturing unit (Planning for product & area) PAGE NO. 1 2 3-5 6 7 8-9 10-16 17-46 9 10 11 12 13 14 15 16 Total work force Machines in section Specific market Growth Market Market size & share Research & Development Cost statement for business Balance sheet for business plan 47 48-51 52 52 53 55 56-57 Executive Summary Patad will enter into the Apparel Business in the year 2013 on 5 November, with a group of 16 members, the Entrepreneurs. “PATAD “has the mission to decorate and design each of customer’s thought and thus successful in creating a niche market for trouser lovers. The start-up will have to face major big players in the market but soon with our USP of Quality product & Customer satisfaction, we will trap the market. We hope then new Opportunities start and our Trouser manufacturing unit start flourishing. We planned to produce 2500 quality trousers per day with 96% quality performance. The need for use of efficient distribution and financial methods in these plans are to develop our brand value. So on time delivery makes us for efficient distribution channel. We are planning to establish 3 major DC in Bangalore, New Delhi & Mumbai. We have several retailers who are willing to place large orders within the next three years, instead of market slowdown. Several other prospective have expressed serious interest in doing business within six months. Over the past few years we spent much time studying ways to improve overall performance and increase profits. This plan is a result of that study. The basic components of this plan are: Product strategy 1. Competitive pricing 2. Expand the markets 3. Increased advertising 4. Lower our unit costs, 5. Thereby achieving higher profits. Service strategy 1. Sign contracts 2. Increased advertising 3. Effective & Technical staff To this end, we invested A total of $3,00,00,000 which will be used to finance working capital, plant and equipment. The company will soon be incorporated and common stock issued to investors. The company will be run as a, partnership. VISION To set a precedent in the global garment manufacturing industry through continuous innovation and perfection of Designs, superior quality, exceptional products, focused services and enhanced customer satisfaction. MISSION To decorate and design each of customers’s thought and thus successful in creating a niche market for trouser lovers. GOAL To have a healthy, successful company that is a leader in customer service and that has a loyal customer following GENERAL COMPANY DESCRIPTION Panache Fashions is mainly in Producing & marketing Trouser. The major point is to target high class customers. The mission of company to specify customer needs and fulfil it on time at lower cost. Our goal is to achieve profit level of $ 4500000 within 3 years. We want our business to be at 3-4th top most position within 5 years. Objectives are progress markers along the way to goal achievement. The company is located at the heart of Garment Industrial Area and it is nearly 15 Km away from the heart of Bangalore city. The location will be more convenient as it mainly works as a jobber unit of different garment manufacturing industry. Business Philosophy is producing Quality & designer product & maintaining proper Supply chain. The manufacturing Unit & owned sales point make it more useful and effective. The market for our product is the high middle class people who love quality product & like new trends in market. Marketing Plan section has to be more effective regarding customer satisfaction & advertising product. The initial markets are few big & matured retailers, then slowly build our own market & make brand value. Brand value creating & maintaining long term relations are our key points. The production will strengthen our supply & in any critical situation we are able to feed our market & retain brand value. This will play vital role in making our brand stable & effective. This is our major strength. The core competition is with the local players as mentioned above & some new trouser retailers also. But the goal to achieve consistent quality at lower price is our USP & strength. The staffs with proper educational background & expertise in their field make this mission more effective. The skills in field & proper supervision by all board of directors make this unit more valuable & make to move in specified direction. Our firm ownership is partnership. The revenue is also generated later by distributing shares among local market. This firm we selected because all the person heading are expertise in this very field & chances of success is more because we all are following 3 points of.. • CONCEIVE IT ….BELIEVE IT……………. & ACHIEVE IT! MANAGEMENT PLAN Target Sales growth in 3 years is 4500000 USD; Get market share appx. 15% till the span of 3 years. Formulated advertising budgets & campaigns. Pioneered new distribution channels. Established national sales force. Achieve BEP in 1 year. Open a brand outlet for trousers. Established national repair & service centers. Production unit should have high & quality production capacity. The production unit have New modern machines with latest technique. Designed point-of-purchase materials Increase new connections with growing retailers. Plan growing retail players & sourcing team. Brought new and innovative products to the market. . Launch our web site for effective promotion of our manufacturing & Product. Plan is to form our own brand outlet after 3 years. is responsible for marketing. She then completed her Masters from NIFT and now working as effective BOD. accounts payable. interaction with auditors. NASEEB AHMAD . is Responsible for financial operations. He will take care of all Issues regarding Marketing. He has had 1 Yrs experience in this field. 2. • • Avanish Dwivedi. Then he worked for 1 year in production.BOARD OF DIRECTOR 1. is member of Board of Directors. He then completed his Masters from NIFT and now working as effective BOD. accounts receivable. PRITY SAHAY is member of Board of Directors. is member of Board of Directors. Prity Sahay is graduated from the University of Mumbai in 2007 with a bachelor’s degree in computers. Miss. He has had 2 Yrs experience in this field. 3. ORGANIZATIONAL STRUCTURE FOR MANUFACTURING UNIT . He is graduated from the UPT University in 2005 with a bachelor’s degree in Textile. investor relations. Then he worked for 1 year in planning. is Responsible primarily for Production issues. She has had experience in this field. is member of Board of Directors. He has had 1Yrs experience in this field. He then completed his Masters from IIM Kolkata and now working as effective BOD. Jiaul Haque. He will take care of all Issues regarding Finance. human resources and training. Then he worked for 2 year in production. She will take care of all Issues regarding Management Policies. sales and sales support All other responsibilities will be distributed among other all staff under proper supervision of these all Board of Directors. RESPONSIBILITIES • • Prity Sahay is Responsible for entire Management operation. 4. He will take care of all Issues regarding Production. JIAUL HAQUE. AVANISH DWIVEDI. Naseeb Ahmad. He then completed his Masters from NIFT and now working as effective BOD. He is graduated from the Amravati University in 2006 with a bachelor’s degree in Textile. He is graduated from the Kolkata University in 2006 with a bachelor’s degree in Textile. FOR RETAIL SECTION PLANNED . This offers customers the best possible solution.PRODUCT/SERVICE DESCRIPTION Panache Fashions intends to offer fashion TShirt. TROUSER Offers the lowest price on the market Offers the Quality trouser in the market . 5 years. Increase our continuing education and training expense. Present market is estimated at $2 crore. We will meet this challenge by: 1. we expect advances to be made and competitors to arise and offer similar services. cost effective way for them to realize a similar goal. Even though the technology used to create this product is new. 2. 3. Make regular investments in new equipment. we will need to devote approximately 28% of revenues toward research and development. financial. We have a trademark & marketing rights for Panache Fashions product/service. Also due to the fast changing nature of this industry. Even though at this time our expertise is unique in the marketplace. OBJECTIVES LONG TERM Panache Fashions believes very strongly in technical. Saves the time and money for customer for value added product. we will need to retrofit these machines within 15 years. To remain on the leading edge of this product. SERVICE Provides a service which is not presently available in this area. Hiring staff specialized in these new areas. Overnight delivery in case of more demand. The product has a useful life of 5 years. 2. 4. we expect that others will be able to substantially reproduce our patented results within 10 years. To distribute this product so that it remains usable for our customers. Shipment within two weeks to distributors. . 4. Is strengthened by a team with combined experience of more than Avg. Adding complementary lines. Our goal for market share is 10-15% with in 3 years. Is the most technically advanced Offers more useful features Saves them time and money Offers users better value per Rupee spent Provides an alternative way to achieve a similar task. Our manufacturing plan has considered this. Clean & proper storage 3. Specially padded boxcars. This will last until 2050 at which time it may be extended for 10 years. we must use the following methods of storage and transportation: 1. business and moral excellence. This agency agreement is cancelable upon 60 days written notice. To secure a stable future for all those connected with pp we have set the following long term goals. Provides an alternative. ) Community involvement (Rotary. Therefore. MAJOR COMPETITORS There are many major competitors of trouser in India. there is a great competition in this business. 3. employee benefit program for continuing college education. Maintain state-of-the-art accounting system for careful tracking. Set up. Budget for necessary seminars and/or continuing job-specific education. Increase productivity by investing in employee training and education.We want to be considered by our peers to be the market leader in sales as evidenced by: High end of scale in financial ratios Major market share Trade industry awards Technical excellence (awards. Budget for complete computer training for appropriate applications. 5. honors. etc. Support company involvement in various local and national charity events. The main competitors are: . Monthly reports on financial status of the industry. 2. etc. United Way. First Year 3. 4. Third Year 4. Fourth Year -2% 10% 10-15 % 2. 1.) SHORT TERM Market share goals 1. Aggressive recruitment of the best technical staff in the industry. Second Year 0% Maintain costs through acquisition of new plant and equipment. They produce very good quality trousers with minimum cost in limited time. 6. Old names in industry & good experience so difficult to find loop holes. Pricing . known for aggressive pricing policy. Ltd. COMPETITIVE ANALYSIS (Rating is from 1-5 to evaluate our group) Madura Factor Panach e Streng Fashio th ns Weakne ss Peter Prov Wills Style Levis garm-ents England ogue Life Raym- Arvind onds Brands Products Trousers Quality No Brand image All Trousers Trousers Ladies All All All . Gokuldas Images. etc. WEAKNESSES Service -.Not proper service as already big names so not concentrating on this. Peter Englamd Provogue Raymonds Wills lifestyle STRENGTHS Location . Manufacturing – Mostly outsourced so delivery & SCM control not up to extent . on major artery. Overhead – Overheads are more due to giants in this area. Management Everyone has an MBA from renowned Univ.ships to anywhere in the world.Low cost producer. Dedication – Staff not fully dedicated as big brand so no proper supervision. Delivery . close to terminal.♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ Arvind brands Madura garments Intimate Clothing Pvt.next door to Panache Fashions factory. Madura Factor Panach e Streng Fashio th ns Weakne ss Peter Prov Wills Style Levis garm-ents England ogue Life Raym- Arvind onds Brands Price (RS) Quality Selection Service Reliabilit y Stability Expertise Company Reputati on Location Appearan ce Sales Method Credit Policies Advertisi ng Image 500-1500 IN range Not for Lower Cost more Not total market Not all cities Not popular 700-1500 500-1700 10002100 1 1 12002300 2 2 17003200 1 1 700-1200 1000-1300 2 1 good Style preference good Avg. 2 2 3 2 3 2 2 2 1 2 3 1 3 3 2 1 1 1 2 1 3 2 2 1 2 So stable Not develop market New in field New ideas Do 2 2 3 2 3 3 3 4 2 3 2 2 3 1 1 1 1 2 1 3 2 3 2 1 Heart of bangalore Costly 2 2 1 1 1 2 2 1 1 2 1 1 1 2 1 3 Good & New so take effective time to adopt Have to Cant give so give much With new methods Yet to developed 2 2 2 2 2 1 1 2 3 3 4 4 4 2 3 1 4 4 2 3 1 2 1 3 2 3 1 1 1 2 1 COMPETITIVE ADVANTAGES . By keeping our overhead low. we will be able to keep our margins high. Through these economies of scale. By pricing to the market. New thought & concept in this market Sophistication in management and finance. we will work on a pre-pay basis. allowing us to provide internal financing for growth possibilities. many items currently on the market can be sold with lower prices. we will be able to funnel our profits back into operations thus avoiding high debt ratios or lost sales Panache Fashion. we will be able to funnel our profits back into operations thus avoiding high debt ratios or lost sales Panache Fashions. This results in our being the low cost Panache Fashion these price sensitive markets. Because of the nature of this industry. Service The distinctive competitive advantages which Panache Fashions brings to this market are. As a unique service company. we will be able to rent office space in more moderately priced buildings. Sophistication in finance and distribution. By keeping our overhead low. Our targeted minimum gross profit margin for a category must be 10%. A toll-free national number will be used for customer orders and inquiries. Price lists will be updated as needed. MARKETING STRATEGY ♦ Location . With those companies with which we have established a relationship or are known to be financially secure. A level and policy of Capitalization that will allow us to fully address the respective markets with comprehensive marketing and customer service plans. our per unit costs of Panache Fashion decrease and we will achieve higher discount levels from our Panache Fashion. we will achieve higher sales and therefore increase our buying power. we will print complete four-color catalogs on a yearly basis. As the amounts of our purchases increase. but also according to what the market will pay. yet a higher net profit. The philosophy of Panache Fashions is to price not just according to our costs. yet still provide quality service to our clients and customers. A quarterly direct mail campaign directed at both current customers and prospective new customers consisting of an informative newsletter. This allows us greater discounts. A level and policy of Capitalization that will allow us to fully address the respective markets with comprehensive marketing and customer service plans. We intend to be aggressive in trade magazine advertising. Our initial marketing campaign will allow us to book a sufficient amount of business so that we can impleusnt our telephone customer service Panache Fashions program. We are able to run an efficient and lean structure.Product The distinctive competitive advantages which Panache Fashions brings to this market are. Personal contact with production related businesses in the area will be our main focus for promoting Panache Fashions.com . COMPETITION Get the USP of all competitors in the market & try to compete with our USP. A web page will be set up at a “free” web site. Give fair discounts time by time. This Pricing strategy will make them competitive in the market and allow them to cover the costs. The finished product will be placed in a plastic bag to protect it until it is delivered to the customer. Business cards. Give good margin to our retailer & reduce our profit margin at less extent. to those we meet. will introduce ourselves. ORGANIZATIONAL PLAN FOR MANUFACTURING UNIT BRIEF FOR TROUSER UNIT . As it is located in the Garment Industrial Area. The strategy of working is not only relation with public but also to get full customer satisfaction. Exhibition of the products held in the different parts of the world. the labours are easily available. letterhead and thank you cards will be printed for business activities. the area in which they desire to do business. We also participate in different fashion show. initially to see if there is any business potential in this area at this time or in future.panachefashions. The major strategy is 100% Guarantee for the product & return of money within 20 Days on providing sales slip. ♦ Public Relations As owners of “Panache Fashions”. Gift vouchers & Assured gift. organized shop that presents an appearance of classic quality that will last for a long time. and business. the USP we Operate the business & retail. Power supply is also good as required for the industry and as per the Government policy to control Pollution it is away from the main city. while they are growing. Some brochures put together identifying the type of products we offer. www. ♦ Price / Quality Relationship “Panache Fashions” plans to provide a high quality product at a moderate price. ♦ Presentation To Customer “Panache Fashions” plans to runs a neat. to get our strong competition. Their quality service and convenience will be what makes them stand out in the local industry.“Panache Fashions” is located at the heart of Garment Industrial Area and it is nearly 15 Km away from the heart of Bangalore city. The brochures will also describe our business. ADVERTISING Registered the as the member of the Apparel Export Promotion Council (AEPC) and an ad appears on the yellow pages (Industry directory website) describing our services they offer. The location will be more convenient as it mainly works as a jobber unit of different garment manufacturing industry. PURCHAS DEPARTMENT/SOURCING 5. MERCHANDISING 8. CAD 10. FABRIC/TRIM STORE 3. ELECTRICAL/UTILITY 15. ETP Details of activities of each section are discussed below to emphasize the client’s requirements in building the above mentioned trouser manufacturing plant. WASTE DEPT 10. MEDICAL PRODUCTION BLOCK 1. QUALITY 9. TECHNICAL DEPATMENT 16. CANTEEN 20. IED 11. MAINTAINANCE 18. PRODUCT PLANNING AND CONTROL 17. EDP 13. FINANCE 4. SERVICE BLOCK 1. ADMINISTRATION 2. LAUNDARY 7. HUMAN RESOURCE 3. CRECHE 19. DATA ACQUISITION 14. SEWING 5. FINISHED GOODS WAREHOUSE 9. HUMAN RESOURCE DEPARTMENT • • • Recruitment of employees Determine the wages/salary structure Arrange Training program . PRODUCT DEVELOPMENT AND SAMPLING 2. CUTTING 4. MARKETING 6.The Trouser manufacturing plant comprises of Production block Service block SERVICE BLOCK 1. FINISHING AND PACKING 8. KAJA BUTTON SECTION 6. IT DEPT 12. COMMERCIAL 7. The reception is located adjacent to the visitor’s lobby. The major activity in the reporting room would be keeping record of the incoming and outgoing trucks. The parking spaces for trucks are allotted near the docking area. addressing complaints. draperies and tables. 1.• • • • • • • • • Implementing and evaluating the factory policies Organizing events Redressing grievances. The receptionist desk shall be well designed one with good aesthetic visual appeal. File racks and lockers are provided for HR staff also. 1. They are also provided with desktops. chairs. It will showcase them in contemporary style with an aesthetic appeal. The parking space should be separated for four wheelers and two wheelers.4 FIRE SAFETY . Desk be furnished with stationeries and connected by telephone networks.3 PARKING It is desirable to locate the parking space near the main entrance. Taking care of the welfare of the employees Evaluating employee performance and giving rewards Taking care of employee safety and health hazards Maintaining record of attendance Reception for attending visitors and regulating call services Arrange contract for security. The visitor’s lobby shall be well furnished with sofas. vision and values. The Manager and the Assistant Manager shall have separate cabins. 1.2 RECEPTION & VISITOR LOBBY The reception will serve as the foremost entry point for the administration block. The allotted parking space shall accommodate 8 -10 four wheelers & 80-100 two wheeler in parking space. The visitor’s lobby should be spacious enough to accommodate around 10 people. The visitor’s lobby is located adjacent to the reception area. people moving in and moving out. The Manager and the Assistant Manager have separate tables and few chairs in their cabin along with file racks. The space for reception should be sufficient enough to accommodate the receptionist desk and a chair for one receptionist.1 SECURITY The main entrance for the factory should be big enough to facilitate truck entry and exits. A security post as well as guest reporting room to be considered situated near the main entrance. while the rest of them have separate table and chairs with desktops & printer. It shall serve as the introduction to the company’s mission. It should be sufficient enough to accommodate three trucks at a time. values followed by the company and its business ethics. The reporting room shall accommodate 5-6 people. The visitor’s lobby shall also house a design layout of the entire factory. canteen and house keeping The human resource department comprises of 7 people including the manager and his/her assistant. 1.2 for each. It should have the capacity to accommodate 70-80 people. there should be a travel path to facilitate “fire service truck” movement in case of fire accidents. • Preparing tea and coffee • Preparing food for the workers and the staff members • Billing and service counters • Cleaning the canteen and the utensils • Providing tea/coffee to the staff at regular intervals • Providing refreshment to the guests as per the requirement • Provide service at lunch/ refreshment time.Around the factory. 1. It should also have separate space for drinking water & food. The refreshment rooms have double entry and double exits.5 DRINKING WATER & TOILETS Drinking water shall be kept in suitable vessels in a clean state at appropriate locations all around the factory. first aid also should be required. Appropriate signboards shall also be provided.7 • • • • CRECHE Taking care of the kids of the workers Feeding the children Involve them in some kind of playful activities Provision for taking care of the infants for sleeping Crèche is for children so having facilities of toys & games. All safety measures like fire safety devices. The department consists of 3 staff. The canteen should also have space for fire extinguisher & other safety devices. HRD Manager Assistant Manager 1 1 . 1. Hence its seating capacity shall be same as the number of people. The kitchen is furnished with equipment to prepare coffee and tea with an automatic vending machine.6 CANTEEN The refreshment room for the service and managerial staff are to be located at any corner in the service block cut-off from the rest of the activities and should have direct exit. It should be capable to accommodate 2 staff & 40-50 children. The toilet facilities be located near departments at a specific distance form them to avoid the smell and stink affecting the departmental workspace. Fire safety zone design should be provided for about 550 people. For every 25 members there shall be at-least one toilet. 1. It also has kitchen attached to it. 1 executive chair & table for doctor. Separate place for 2 staff nurse with 1 table & 5 chairs. There shall be first aid and medical assistance room catering to the eventualities. ADMINISTRATION . Executive Executive Compliance Executive Site Engineer Receptionist Welfare Officer Driver Cook Helper to cook Crèche Security Office Boy TOTAL 1 1 1 1 1 1 1 1 1 2 2 9 1 25 MEDICAL Keeping and upgrading the first aid boxes in all the departments regularly Doing regular checkup for the workers and staff members In case of any accident or emergency taking immediate action Conduct exercise for the workers during the working hours for a while in order to avoid fatigue. • • • • 3. Medical having cabin for doctor (who visit the industry daily for 3-4 hours) .Security Head Sr. MEDICAL Doctor Staff Nurse TOATL 1 1 2 2. Also space to keep medicines safely in storage place & 1 place for wheel chair. • Maintain Ambulance for any emergency. some more chairs to accommodate people waiting for him. Planning the expansion of business for generating more profits Defining business strategies and implementing new technologies Monitor the performance of production dept. Top level management is responsible for taking the major decisions Planning the annual budget with coordination of finance dept. FINANCE • • • • • • • Keeping track of business transactions Making annual budget for the factory Raising funds for the business Keeping track of overall daily expenditure Payment made for procured goods Preparing balance sheet Releasing salary as per the pay slip issued by the HR The finance department comprises of 7 people including the manager. locker & Printer. 3 for each. Conduct meeting daily on daily basis. File racks and lockers are provided for staff also. The factory system certificates. will be addressing people from various departments etc. This cabin will be equipped with telephone . desktop and cupboard. 4. There room will also connected via ERP software and furnished with internet facility.desktop & separate printer. staff should have automatic common printer at centre place. The Manager should have separate cabin with table . locker & telephone . quality certificates and other distinguished awards will show cased in there room. ADMINISTRATION GM production Factory Manager Total 1 1 2 The major activities of this. They have a separate cabin furnished with manager’s table and 5-6 chairs. The rest of others have separate table and chairs with desktops.4-5 chairs along with file racks. FINANCE Manager 1 . delivery dates. quality report. PURCHASE DEPARTMENT/ SOURCING – Vendor selection – Raising indent/PO – Sending PO to supplier/s – Price determination/negotiation with the supplier/s – Taking follow up from the suppliers – Solving financial disputes (if any) The Purchase & sourcing department comprises of 5 people including the manager.Executive Officer Accountant Helper TOTAL 2 2 1 1 7 5. desktop & separate printer. 1 for each. MARKETING – Approach to new buyer – Introduce/advertise for the company – Study of strong competitors in the market – Working on marketing strategies and building strong USP for the product The marketing department shall accommodate the 9 marketing staff including a head of the department.4-5 chairs along with file racks. order status. The major activities include processing information regarding order placement. chair. cupboard. telephone . File racks and lockers are provided for staff also. etc. All the marketing staff shall have separate table and chair with desktops. telephone . while the head of the department shall have a separate cabin furnished with table. The rest of others have separate table and chairs with desktops & automatic common printer at centre place. TOTAL 1 2 1 1 5 6. There is also a Fax machine required at common place near to printer. All the desktops are linked via ERP software. locker . PURCHASE AND SOURCING Manager Fabric Sourcing Executive Trim/Accessories Sourcing executive Sourcing Asst. Telephone lines are also provided for each staff. All the activities are confined to desktop. The Manager should have separate cabin with table . . 4-5 chairs along with file racks.Telephone lines are also provided for each staff. File racks and lockers are provided for staff also. 1 for each. All the desktops in the marketing room are linked via ERP software. Telephone lines are also provided for each staff. MARKETING Manager Sr. Executive Officer TOTAL 1 2 6 9 7. The application server for the marketing room is housed in the room itself. locker . COMMERCIAL Manager Sr.telephone. The rest of others have separate table and chairs with desktops & automatic common printer at centre place. Executive Officer TOTAL 1 1 2 4 8. MERCHANDISING • BOM generation • Sending and receiving mails to the buyer . COMMERCIAL DEPARTMENT • • • • • Maintaining an taking care of the logistics Custom clearance Define business terms Generating and collecting documents and present it to the bank or the buyer Discrepancies are taken care The commercial department comprises of 4 people including the manager.desktop and cupboard. cupboard. desktop & separate printer. The Manager should have separate cabin with table. All the desktops are linked via ERP software. attending telephone calls. 4-5 chairs along with file racks. The merchandiser’s room will accommodate the Senior Merchandiser and his/her staff. It will also consist of an application server. All the desktops in the merchandiser’s room shall be linked through ERP software & printer. The Senior Merchandiser’s cabin shall also have chairs to receive 5-6 People in his cabin & capacity for 4-5 waiting. Merchandiser Total 1 4 4 9 9. . The merchandising staff including the Senior Merchandiser will be 9. Model merchandising charts. etc. The major activities shall be desktop job. The rest of others 6 (Sr. telephone. desktop & printer. The file racks shall be three in number and file racks two in number. shrinkage.5 AQL • Panel size checking • Panel quality checking • Inline checking • End line checking • Presentation checking • Final checking after ironing • Measurement checking • Final audit at AQL level as per buyer’s instruction • Random quality audit by QC The Quality department comprises of 51 people including the manager. cupboard. while the others shall have separate tables and chairs. QUALITY • Fabric inspection (4 point system) • Fabric testing. file racks and lockers. The Senior Merchandiser shall have a separate cabin. MERCHANDISING Senior Merchandiser Merchandiser Asst.gsm. Time and action charts will be displayed in the merchandiser’s room. locker. SOP’s. epi /ppi • Shade sorting (grouping) • Trim quality inspection at 2. replying through emails and calls. All the desktops are linked via ERP software. Executive & Executive) have separate table and chairs with desktops. The merchandising room shall have file racks and cupboards for stacking files and approved samples. 2 telephone lines are also provided for staff.• • • Making the tech pack for newly developed styles Revising the samples according to the buyers comments during the sampling process Taking follow up from the concerned dept. The Manager should have separate cabin with table. shrink. The desktops are linked via ERP software. CD holders. The Operator has separate table and chairs with desktops & a plotter (72 inch). combine. cut. Removing and adding patterns The CAD department comprises of 4 people including the manager. cupboard. Rotate pattern. locker. CAD • • • • • • • • • • Digitization On screen pattern construction Grading done on size basis. stretch. The Manager should have separate cabin with table. desktop & separate printer. File racks and lockers. Executive Executive (Cutting) Executive (Sewing) Executive (Fabric & Trim) Quality Controller Auditor (QA) End line checker In Line Checker Fabric Checker Final Checker Panel/Peripheral Checker AQL auditor helper Total 1 1 1 3 1 3 3 3 9 3 18 2 2 1 51 10. . trace. 2-3 chairs along with file racks. Manager Sr. 1 telephone line etc. Digitizer board at other side. Size correspondence Piece assembly Marker planning Plotting Piece rotation Pleats.QUALITY ASSURANCE DEPT. flip. telephone. telephone. The Manager should have separate cabin with table. CAD CAD In-charge CAD Operator Helper TOTAL 1 2 1 4 11. . Manager Sr. DEPT. preparing the markers and taking their printout. locker.Proper area required for digitizing the patterns. IED (INDUSTRIAL ENGINEERING) DEPARTMENT • • • • • • • • Perform time study Perform motion study Operation breakdown of all styles Line plan Line balancing Skill matrix Hourly production monitoring First hour efficiency loss calculation INDUSTRIAL ENGG. cupboard. Executive Executive Computer Operator Method/Technical Executive Time Study operator TOTAL 1 1 2 1 3 8 16 The IED comprises of 16 people including the manager. desktop & separate printer. 4-5 chairs along with file racks. cupboard. 3 File racks and lockers are provided for staff. locker. They should have separate cabin with 1 table. 2 Telephone lines are also provided for staff. telephone. The others 3 have separate table and chairs with desktops & automatic common printer at centre place. desktop. The Manager should have separate cabin with table. 3 File racks and lockers are provided for staff. All the desktops are linked via ERP software 12. wires. CD etc & a white-board. cupboard. • • • .The others 5 have separate table and chairs with desktops & automatic common printer at centre place. Planning performance evaluation The PPC comprises of 4 people including the manager. 4-5 chairs along with file racks. 4 chairs along with file racks. The desktops are linked via ERP software. Manager Executive TOTAL 1 1 2 4 13. marker to guide if any technical problem arise. IT (INFORMATION TECHNOLGY) DEPARTMENT Updating the company’s website Resolving the errors in the website Checking the hardware and software updates available and install new ones if required • Explaining the functions of the software to the employees who will be using it ERP department comprises of 2 assistant. All the desktops are linked via ERP software PPC Manager Asst. 2 Telephone lines are also provided for staff. PRODUCT PLANNING AND CONTROL • • • • • • • Prepare time and action calendar Breakdown of the order received from the buyer Scheduling Organizing preproduction meeting Send PO to all concerned departments Follow up from concerned dept. A place to keep the circuit. telephone . desktop & separate printer. locker. desktop & separate printer. EDP EDP Executive TOTAL 1 1 15. The enclosed cabin shall also house batteries. It is stressed that this department is temperature regulated. 1 File racks and 1 locker. Place also to keep accessories & small computer parts. • • • • • DATA ACQUISITION Record the production Dispatch/ issue record slip maintenance Record actual production per day & hour Producing actual production report Inform to top management in alarming situation The Data department comprises of 10 people including the manager. So will be provided with 1 table and 3 chairs. The Manager should have separate cabin with table. locker & telephone .4 chairs. The department staff is 1 in number. The space accommodating the database servers will be an enclosed cabin inside the EDP department. Internet net router etc. 4-5 chairs along with file racks. EDP DEPARTMENT • Maintaining connectivity of ERP • Computer maintenance and technical support • Telecommunication maintenance • Antivirus upgrade/ software upgrade etc • Assistance for new software implementation • Maintenance of external hardware also like printer. and other maintenance equipments required for the server maintenance. 1 table . 1 File racks and 1 locker also for Production writer. This dept have a separate wooden shelf to keep networking hub. The System Officer have separate table and 4 chairs with desktops. . digital camera etc The EDP department shall house all the database servers. plotter.IT ERP Asst TOTAL 2 2 14. • At the end of every month. desktop. A stock register is maintained which gives an idea of the machinery stock for the factory. 4-5 cupboard . Electrician Mechanic Boiler Operator 1 1 2 4 1 . MAINTAINANCE AND UTILITY Sr. The dept. ELECTRICAL/UTILITY DEPARTMENT • • • • • Maintain electrical equipments . wires. Sewing Attachments & work aids. bus bar management Transformer /MCB/generator maintenance Compressor/boiler maintenance Electrical safety and routine checking Maintenance of Band knife & Straight knife. MAINTAINENCE DEPARTMENT Maintenance of all the machinery on sewing floor. a stock statement of machinery & spares is generated & sent to HO.DATA ACCQUISITION System Manager System Officer Production Writer TOTAL 1 1 8 10 16. Desktops is linked via ERP software. • • The cupboard with locking system for keeping Electrical instruments.4-5 chairs along with file racks. • Help during new batch setup The department comprises of 9 people.telephone . Mechanic Electrician Asst. • Keep buffer of the spares. have big cabin with table . PRODUCT DEVELOPMENT AND SAMPLING Product development • Inspiration • Theme selection • Style board • Fabric/trim/accessory selection • Market research • Making silhouette • Develop the sample Sampling • • Manual pattern making Fabric cutting for samples . have cabin with table . 2 cupboard . PRODUCTION BLOCK 1. The dept.telephone . TECHNICAL DEPARTMENT • Spec sheet development • Spec sheet evaluation sent by buyer • Determining level of technology of machine required • Solving any sort of technical problems The department comprises of 2 people.Total 9 17. Desktops are linked via ERP software. racks and chairs in the service block shall constitute 40% of the total building space. TECHNICAL Garment Technologist 1 Helper TOTAL 1 2 Note: In overall. desktop. The pin-board for new sewing technology display.3-4 chairs along with file racks. the tables. cupboard. desktop & separate printer. PRODUCT DEVELOPMENT AND SAMPLING Manager Development Executive Sampling Supervisor Pattern Master Tailor Spreader Cutter Ironer Helper TOTAL 1 2 1 1 10 2 1 1 2 21 . locker. The Manager should have separate cabin with table. 3 File racks and lockers are provided for staff.• • • • • Sewing the samples Fit analysis on the dummies Pressing Measurement checking If problem arises in fit/measurement manipulate the pattern PRODUCED SAMPLES • • • • • • • Development sample Proto sample Salesman sample Fit sample Green tag sample PP sample Size set The Sample dept. comprises of 21 people including the manager. All the desktops are linked via ERP software. 1 Telephone lines is provided for staff. 4-5 chairs along with file racks. telephone. The others 5 have separate table and chairs with desktops & common colour printer at centre place. One big rack for keeping the patterns for reference. Provide space for bulk. Besides the service staff. aisle space. rack. The stores shall have a space to store fabrics. It also stores Fabric roll. accessories and trims of varying densities. spare parts for the machineries. The object is also to keep near to exit gate so while input of material truck will easily reach at store. loading and unloading staff are also there. And it shall have two exits. receiving and shipping space. Issue the trim to swing dept. as per order. FABRIC/TRIM STORE DEPARTMENT • • • • • • Receive the raw material Check the delivery challan Do fabric inspection using 4 point inspection system Record input. They are 11 in number. The stores service staff are 5 in number. All their activities are linked through a ERP software. Apart from the storage space. . Each of them are provided with table. The main intention is to provide a dry environment for the purpose of storing goods and material that require protection from the elements. FABRIC & TRIM STORE Manager Assistant Helper Total 1 4 11 16 TRIM STORE AREA CALCULATION Cabinet size = 2x2x2 qft. one in docking area and the other near cutting section. issue &balance Issue fabric for cutting as per day planning. packing and crating space.2. there shall be docking space for one truck at a time and space for accommodating stores service staff. The loading/unloading equipment includes forklift and manual both. and bin storage. chair and a desktop. The stores shall have a direct entry from the docking area and an entry from service block as well. Trims Required Main label = 2500 + 2 % extra per day = (2500+50)x20 for 20 days = 51000 units = 510 bundle each of 100 unit Care label Size label Jocker label = 510 bundle = 510 bundle = 510 bundle cabinet required = 10 Button Requirement total quantity = (2500+50)x5x20 = 255000 units = 255000/144 = 1770 gross for 20 days Cabinet required = 2 for buttons Sewing Thread Requirement Over lock thread = 221x2500x20/5000 = 2210 cones each of 5000 meter Button Sew Thread = 3.5x2500x20/5000 = 35 cones Label Thread = 1x4x2500x20/5000 = 40 cones Pocketing Thread = 11x2500x20/5000 = 110 cones Shanking thread = 0.5x3x2500x20/5000 . size 5 feet x 3 feet One table and chair for store Incharge Total area required for trim store = 25 feet x 18 feet = 450 sq feet . avg length 6.= 15 cones Tacking Thread = 1x2500x20/5000 =10 cones Bobbin Thread = 81x2500x20/5000 = 810 cones Binding Thread = 1x2500x20/5000 =10 cones Top Stitch thread = 14x2500x20/5000 = 140 cones Box size containing 10 cones = 12 inchx 6 inch x 5 inch one cabinet accommodate = 40 box total cones required cabinet required Zipper Required = 3380 = 10 = 1x(2500+50)x20 =51000.5 inch cabinet required waist band curtain =5 = 1.2x2500x20 = 60000 mtr = 60000/300 = 200 rolls cabinet required =1 cabinet required for tags and poly bags = 2 total cabinets = 30 Area required for racks = 10 feet x 14 feet Trim inspection table = 2. 007x.91x3000x20/200) = 2 rolls (0.5 = 4500 mtr = 4500/150 = 30 rolls / day Fabric required / day For 20 days = 30x20 = 600 rolls Pocket fabric Interlining Pocket binding Total Rolls • • • • • • • • = 80 rolls (0.5 mtr Capacity = 2500 garments/day Garments to cut = 2500 + 20% extra = 3000 per day = 3000x1. 15 roll in each section) Rack size = 11 feet x 5 feet (2x4. 15 roll in each section) Space for Trolley = 15 feet x 5 feet Inspection Machine = 5.91x3000x20/200) = 702 Roll Dia = 10 inch Require 2 rack for 600 rolls (body fabric) Rack size = 27 feet x 5 feet (5x4.27x0. CUTTING • • • • • • • • • Receive production plan Receive work orders Receive fabric Prepare cut plan Spreading Fabric consumption cross checking Cutting Ticketing Bundling .064x.FABRIC STORE AREA CALCULATION • • • Body Fabric consumption = 1.91x3000x20/200) = 20 rolls (0.7 feetx 6.5 feet Inspection table = 5 feetx 3 feet Weighing scale = 4 feetx 4 feet Total area of fabric store = 44 feet x 28 feet = 1232 s ft 3. telephone . cutting machines. desktop & separate printer. locker . The cutting room shall accommodate spreading tables. Plaid matching involves fine work. CUTTING ROOM CAPACITY . cutting the lay. cupboard. bundling and stickering tables. The light need to shine directly onto the exact area where the fine work is being carried out. fabric racks and material handling equipments. The cutting activity will generate noise. Rest of the parts of the cutting room shall have regular lighting requirements of minimum 65 lux in the horizontal plane at a level of 90 cm above the floor. CUTTING Manager Cutting In charge Spreader (Auto Spreading) Spreader (Manual) Cutters Band knife cutters Re-cutters Ticketing Fusing helpers Total 1 1 1 4 3 1 2 12 8 33 The cutting in-charge have separate table and chair. stickering the panels and storing them. The desktop is linked via ERP software.• • • • Lay slip generation Re-cutting Fusing Feeding to batch The cutting department comprises of 33 people including the manager. The cutting room shall have entrance big enough to move fabrics from the store to the cutting room by means of material handling trolley. The Manager should have separate cabin with table . bundling the cut parts. The major activities in the cutting room are spreading the fabric. Ensure the cutting activity space is sufficient so that the decibel level shall be below 85 dBA. hence the adequate lighting of the order of 100 lux in the horizontal plane at a level of 90cm above the floor be provided.4-5 chairs along with file racks. There shall be only artificial light in the cutting room. Personal & Fatigue allowance @11% = 4.P. 4. Policy Allowance @3% = 1. SEWING DEPARTMENT • • • • • • • • Cut parts received from cutting section Parts stocked in racks Parts preparatory Random garment inspection by supervisor/Floor In-charge/ A. Total Time = 48.2 mins. Machine Allowance @ 10% = 3.Lay Length = 9 mtrs No of plies per lay = 60 Total length of fabric = Average Roll Length = Rolls required per lay = Roll change time = 2 mins 4X2 = 8 mins 60X9 = 540 mtrs 150 mtrs 540/150 = 3. Total time = (27+3+8)= 38 mins. Garments cuts per lay= 60X6 = 360 units Total garments cut in 8 Hrs = (360X480)/69 =2504 units/shift/table So we require 2 spreading table to cut 3000 garments in one day.2 mins.M Parts number setting Garment assembly section Random garment inspection by supervisor/Floor Inspection by In-charge/ A. Spreading time laying ply = 27 secs Total time for lays of 60 ply= 27 mins.M . Total area of the cutting room = 3850 Sq Ft.4 mins ≈ 49 mins.6 ≈ 4 Total roll change time = Brown sheet spreading time = 3 mins. Cutting Time= 20 mins Total spreading & cutting time = 69 mins.P.8 mins.2 mins. Contingency Allowance @3% =1. desktop & separate printer. The Manager should have separate cabin with table. The sewing department comprises of 355 people including the manager. the illumination requirements should be 100 lux at a level of 90cm from the floor. a separate cabin is provided for the sewing maintenance department. sewing preparation operations. The sewing room also generates noise. The racks and the tables shall constitute around 70% of the maintenance department space. sewing maintenance. The lighting requirements should be 65 lux in the horizontal plane at a level of 90cm above the floor. Besides two entrances and exits. So ensure adequate sound proofing inorder to keep the noise levels below 85dBA. It should be near admin or other office place. All the activities are centrally connected by ERP software. This office is not in sewing department. For end line inspection tables located at the end of each line (totally 6 lines). telephone .KAJA – BUTTON SECTION • • • • • • • • • • • • Receive garments from Batch Size Segregation Counter Checking Bartack marking Bartack/ key hole/ Snap.4-5 chairs along with file racks. The machine density on the sewing floor shall be 55% of sewing room space. The maintenance department shall house the maintenance equipment upon tables and racks for storing the spare parts. cupboard. locker . Racks are provided at peripheral of sewing room for storage. Besides the service cabin. . it shall also have emergency exits in the event of fire accidents. The cabin shall also house the application server. etc checking Button marking Button Attachment Shanking Button Hole making Button Hole stitching Alteration back to operator Send for washing The major activities include sewing operations. The sewing room shall have more than one entrance and one exit to facilitate smooth movement of materials and people inside the department. quality and service work. 25 work stations in each row. total 10 working stations in this section. 4 rows in each batch. Waste departments also in sewing section. Width of one batch = 42+5+42 = 89 inch Gap between two batch = 32 inch total width of section = 89x5+32x4 inch = 48 feet Total width including asley six feet each side =48+12 =60 feet . And 30 work stations for preparatory section.SEWING Production Manager Asst. Production Manager Production Executive Supervisors Sewing Operators kaja button section Feeders Helpers Total 1 1 3 3 328 10 6 3 355 AREA REUIRED FOR SEWING SECTION Target output SAM Work stations required = 2500 units/day = 44 min = 2500x44/480 = 230 We plan 2 batch each of 100 work stations. And 10 work stations for kaja button section. The washing department comprises of 13 people including the Section Incharge. The Section Incharge & supervisor should have abin with 2 table 7-8 chairs along with file racks. cupboard. FINISHING AND PACKING DEPARTMENT . locker .LENGTH 25 work station in each row Length = 25x4= 100 feet +space for feeding and end line checking table and storage racks Total Length = 120 feet Total area of sewing section = 120x60 = 7200 sq ft 5.There also required place for chemical storage. WASHING – – – – – – – – – – – – – Fill Water in machine Garments loaded Cycling for 2 – 3 minutes Pour detergents desizing Rinse Enzyme detergent Rinse Softener Unloading Hydro extractor Drier Unloaded from dryer Send to finishing dept. telephone . All the desktops are linked via ERP software. desktop & printer. WASHING Section Incharge Supervisor Operator Helper TOTAL 1 2 4 8 15 6. The finishing & packing department comprises of 65 people including the manager. All the desktops are linked via ERP software. The Manager should have separate cabin with table. The finishing machines be located near the windows to facilitate easier and quick disbursement of steam to the external atmosphere. 1 elephone lines is also provided for staff. locker . final checking. 4-5 chairs along with file racks. telephone . cupboard.• • • Inside Receive garments from Washing unit Style/size/colour segregation Trimming checking • Rough Ironing /seam bursting Outside checking • • • • • • • • • • Waist band ironing Thread sucking Presentation checking Measurement checking Final ironing Folding Tagging Poly bag packing AQL AUDIT Carton packing The major activities in the finishing room constitute finishing operations like pressing &material handling and transport. packing etc. 1 for each. The packing contains folding. FINISHING/ PACKING Manager Production Executive Supervisors (ironing) Supervisor (Packing) Spot Washer Darner Ironers 1 2 1 1 1 1 18 . File racks and lockers are provided for staff also. The rest of others 4 have separate table and chairs with desktops. desktop & separate printer. So proper place for storing is required for it. 8 =9 Ironing table dimension = 5ftx2.5/480 = 7. Tables required for trimming Six trimmer per table time for trimming/unit = 2 min Output/table = 480x6/2 = 1440 units/day So we require 2 tables for trimming for 2500 garments similarly 2 tables required for inside and out side checking respectively.2 ft One stain removing work station = 4 ftx 1. Pressing Tables For seam bursting = 6 For waistband ironing = 3 For final ironing =9 Final ironing time = 1.5 min Tables required = 2500x1.2 ft One thread sucking machine =4 ft x 2.8ft .Folder Helper Packers Total FINISHING SECTION Table size = 12 feet x 6 feet Tables required for sorting 4 workers per table 18 10 12 65 Output/table = 480x4/1 (time required for sorting/unit 1 min) = 1920 units per day So we require 2 tables for sorting 2500 garments. telephone . FINISHED GOODS WAREHOUSE • • • • • Allocate space for storage of accepted and rejected goods Keep the goods ready for loading as per the PO quantity delivery before the specified date at the allocated space Maintain records as per PO number Load the lorry as per PO Give receipt for loaded goods to the concerned person of transportation The finished good warehouse comprises of 4 people including the Section Incharge .One darning station =4 ftx2 ft Two tables for measurement checking Two tables for folding Two tables for tagging Two tables for poly bag packing One cabin for finishing manager = 10ftx6ft Total area of finishing section = 121ftx40ft = 4840 sq ft 7. Proper allocation of quality passed. desktop & printer. awaited & ready to dispatch is notified. All the desktops are linked via ERP software. cupboard. WAREHOUSE Section Incharge Supervisor Helper TOTAL 1 1 2 4 8. WASTE DEPARTMENT • • Collect rejected garments Check the usable/non usable waste .4-5 chairs along with file racks.The Section Incharge & supervisor should have cabin with table . locker . Supply the water to treatment section as – Filtration tank – RO – Pressure sand filter – Activated carbon filter – Chlorinator – Softener Supply the treated water again for washing & other use. Disposal of residual sludge as per environmental norms.• Correct the defected parts by means of removing/matching/ recutting /joining etc The Section Incharge will take all decisions and required steps to correct the damaged garment. This comprises of 2 people including Section Incharge. They required a small space & only one table chair for Section Incharge. The provision also for input of treated water in washing section. washing to ETP plant. They required a small space & only 2 table & 3 chair. WASTE DEPARTMENT Section Incharge Operator Helper TOTAL 1 6 2 9 9. So proper storage should be there for input waste water & output frest water. • • This should be out-side of factory and proper savage should be given for waste water. ETP Section Incharge 1 . Treatment of polluted water for reuse. The water flow should be un-interrupted & directly go from finishing. This is nearby Sewing & cutting so will be helpful in finding the damaged garment and fabric. ETP DEPARTMENT • • • Store the used water from washing in chamber. The Section Incharge will take all decisions and required steps. Supervisor TOTAL 1 2 TOTAL WORK FORCE . NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 DEPARTMENT ADMINISTRATION HUMAN RESOURCE FINANCE PURCHASE DEPARTMENT/SOURCING MARKETING COMMERCIAL PRODUCT DEVELOPMENT AND SAMPLING MERCHANDISING PRODUCT PLANNING AND CONTROL QUALITY CAD TECHNICAL DEPATMENT IED IT DEPT EDP DATA ACQUISITION WASTE DEPT MAINTAINANCE FABRIC/TRIM STORE CUTTING SEWING WASHING DEPT.S. FINISHING AND PACKING FINISHED GOODS WAREHOUSE MEDICAL ETP TOTAL NUMBER 2 25 7 5 9 4 21 9 4 51 4 2 16 2 1 10 9 9 16 33 230 15 65 4 2 2 557 . 131 Unit Cost(US$) 995 Total Cost WATT 130345 72050 . WATT PER M/C S/N 3th OL 131 12 72050 6600 5th OL Automatic Pocket welt B/H DN LS SNLS E/C BELT LOOP DN CS BUTTON SEW BAR TACK HOOK/BAR 4 4 3 3 14 2 5 2 4 3 2200 2200 1650 1650 7700 1100 2750 1100 2200 1650 TOTAL 187 102850 MACHINE USED IN SEWING SECTION MACHINERY SNLS NO.MACHINE USED IN SEWING SECTION MACHINERY NO. US$ TOTAL WATT PER COST M/C Fabric Inspection m/c 1 1500 . DPF-1404) 995 (Brother. BAS 605) 1450 4350 B/H 3 (JUKI MB-372) 1495 (Juki.(Juki. LH 1152-6) 850 (Juki DLN522) 4485 11900 1650 DN LS SNLS E/C BELT LOOP DN CS BUTTON SEWER BAR TACK HOOK/BAR 3 14 2 5 2 4 3 1650 7700 1100 1050 (Kansai. DDL8500-7) 1550 (Pegasus M852) 3th OL 12 1550 (Pegasus M852) 5th OL Automatic Pocket welt 4 4 18600 6600 6200 84000 2200 2200 21000 (Brother. B917) 2650 (Brother KE430C) 5250 1990 10600 2750 1100 2200 1650 TOTAL 187 in US$ 277720 102850 OTHER MACHINES UNIT COST MACHINERY NO. 5 kg) Bulk Washing (200 kg) Hydro extractor (50 kg) Tumble Dryer (50 kg) Boiler Compressor (40 HP) Generator (380 KVA) Computer systems Photocopy m/c Printer Fans Tube lights Water cooler 1 1 2 1 2 18 1 1 1 1 2 1 1 1 1 1 30 1 10 30 550 3 26090 (Oshima K5-190) 26090 4321 (Oshima OB900A/C) 1664 (Eastman blue streak) 750 (Eastman BBB-32) 4321 5000 750 3328 70 750 70 4500 8968 (OP-60LNII OSHIMA)8968 2199 (Reliable 522 HA) 39582 wd steam generator 750 3700 90 15349 (QRS30HPD-125) 15349 25000 30000 (Westinghouse D07) 445 1589 (Xerox Pro 16FX) 30000 13350 21000 1589 1000 1000 35 (Bajaj) 3 334 1050 1650 1002 1200 22000 1125 .Auto Spreading m/c Band Knife Straight Knife Edge Cutter Fusing m/c Ironing Table Spot Washing Thread Sucking m/c Needle Detecting m/c Sample Washing m/c (6. We are able to manufacture our complex product on computer driven assembly lines using the latest in robotics manufacturing. Radio advertisements on weekends. It is our intention to hire the best and the brightest among those currently available. These include retail. 3. Growth Strategy Product . We intend to market our complex product through all the normal channels available to simple product. As we are offering a unique service. we have noticed an increase in demand for branded trousers. A pool of 10 telemarketers. Service Over the past few years. 2. We intend to attack this market very aggressively through the use of: 1. Advertisements in upscale magazines. we intend to initially use commission sales representatives strategically located throughout the country. We also will start a national advertising campaign targeting the end user in various national publications and on national TV commercials.Specific Markets Product Our product has been designed by the latest in computer aided design. informing the public of our capabilities is of utmost importance. Our sales representatives will be chosen based on their own experience in the marketplace. wholesale. To penetrate this market efficiently and swiftly. Our marketing tests included many of the reps we initially would like to hire. Sales calls on real estate management companies. 4. This gives us a tremendous price advantage. Increase number of direct sales reps. is now more skewed towards premium offerings in trousers. is on the upswing.We will increase national advertising and begin targeting smaller accounts and specialty outlets. The womenswear segment and also the trousers segment have grown at a higher pace than the overall industry average in value terms. 3. in terms of value and volume. the trousers market in India registered a growth rate of 13. says the monthly that would hit the stands shortly. Colorplus and Van Heusen in the order. 2. our expansion will be in two separate areas: increasing sales in the India and entering various foreign markets. Expand into neighboring cities. which is an overall growth of 12.230 crore. We intend to develop further sales reps from within by hiring and training them in our own sales .62 per cent respectively.13 per cent in value terms in 2007 over the previous year.5 per cent over 200.401 crore.094 crore in value terms. Expand telemarketing pool to 20. we will conduct in house seminars for various OEM’s demonstrating how the inclusion of complex production into their own products will increase the value of their products.000. the Indian market is currently valued at Rs 78.500-odd respondents in the 15-55 years age group with a monthly household income of more than Rs 15. Nearly 32 per cent of the total respondents had purchased these top five brands. we intend to offer our sales reps the Panache Fashions to sell our products exclusively by joining our company. We estimate that we can achieve 15% market share within 5 years. The premium branded market. This is reflective of an increasing market share being aPanache Fashionsropriated by the organised segment. Finally reaching the goal decided by BOD. After we have reach our first year sales goals. . Service After having successfully completed this entry phase into this market in the geographical are we have chosen. when it stood at Rs 69.74 per cent for the same period. Estimated at Rs 18.950 units sold in 2006. The growth in value and volumes in the previous year was 12. The study took into account only ready-to-wear trousers.53 per cent and 3. which means the market has experienced tremendous value addition during the last one year. Park Avenue emerged the second most popular brand followed by Blackberrys. we will then expand our market by doing the following: 1. According to the IMAGES-KSA Technopak 2007 study.After having successfully introduced the complex product into the Indian market. therefore. This growth gains significance in view of the fact that the volumes Panache Fashion just 3. at 12. The demand. We expect that a small percentage will desire to remain independent and these will have to be replaced with our own sales force. Market Size and Share The market for trouser is estimated at $8 Billion annual sales based on data furnished by Analogue Survey.022 crore units in 2007 as compared to about 1. Allen Solly is the most popular with more than 10 per cent of the 2. The India trouser tale is stitching new trends. A countrywide IMAGES Fashion Survey reveals that among trouser brands. which is quite a sizeable market. Additionally. Levi's. The IMAGES-KSA study observes a general tendency of customers' upgrading to premium brands and labels and thereby driving volumes in this sub-segment. at 10 per cent during 2006 and 2007. Park Avenue . Lee emerged as the most popular brands. except that the volumes growth in this category is much higher as compared to shirts because more and more customers are now experimenting with ready-to-wears. With more women trouser out to work. within women's readyto-wear items. which is only 50 per cent the size of the men's branded market. . though volumes have grown just 3. Wills Sport.640 crore for 2007.The men's trouser market in India.6 per cent. the women's trousers market has also been growing at an impressive 27 per cent in value terms over the past two years and the volume growth has also been remarkably high. Womens wear constitutes less than 30 per cent of all branded trouser sales. valued at Rs 32. More so. has grown 12 per cent over the previous year in value terms. Allen Solly. the share of branded clothing is just 22 per cent. On the brand preferences. Trousers share a similar trend. Possibility of expansion in the area. The location is convenient for our freight companies. We will have renovations costing $836 based upon three estimates. 1. commercial use. The building has the necessary facilities to operate this business. suPanache Fashionsliers. The building is structurally compatible for our use. Location MANUFACTURING The manufacturing unit is in Bangalore. The start-up will have to face major big players in the market but soon with our USP of Quality product & Customer satisfaction. clients and employees. Then slowly shift to our own shop. The rent is below market 3. The better quality we provide the better customer we get.Targeting New Markets To continue our growth. So our target for new market is High-middle class family who love quality but price is also big concern for them. The building is zoned R-3. The retail we plan will be executed after 3 years. 4. . The location will be more convenient as it mainly works as a jobber unit of different garment manufacturing industry. we will be using the following methods to expand our markets and to increase our new areas of doing business: Customer contact – To fulfill their needs Look for quality products Trade shows Government trade leads State Government trade leads Market surveys Research & development The new market is for fashion and money. The area is suitable for manufacturing as because of. We initially dependent on the big retailers in market. We planned to produce 2500 quality trousers per day with 96% quality performance RETAIL This business will be operated at Bangalore.The company is located at the heart of Garment Industrial Area and it is nearly 15 Km away from the heart of Bangalore city. 2. We hope then new OPanache Fashionsortunities start and our Trouser manufacturing unit start flourishing. This location is desirable because: We are renting this building on a 10 year lease. 5. we will trap the market. COST STATEMENT FOR BUSINESS PLAN AREA REQUIRED COST = 22000 Sq. Marketing Plan section has to be more effective regarding customer satisfaction & advertising product. then slowly build our own market & make brand value Research & Development We have already spent a considerable amount in researching and developing our complex product. To this point.5x200 Rs/UNIT = 6.The market for our product is the high middle class people who love quality product & like new trends in market. = 22000 X11 US$ = 242000 US$ BUILDING COST ELECTRICITY FITTINGS = 555555 US$ = 55555 US$ FURNITURE AND OFFICE ACCEESSORIES = 44444 US$ TOTAL MACHINE COST TOTAL FIXED COST RAW MATERIAL COST = 424749 US$ = 1322303 US$ = 1.6 US$ ACCESSORIES = 0. Our next research project will center around using this new Fibre in our manufacturing processes and testing of a new material that has come to our attention. The initial markets are few big & matured retailers.44 US$ FACTORY OVERHEADS = 2 US$/UNIT Depreciation @ 10 = 132230 US$ /YEAR . our research has paid for itself as we have been keying on bringing this new product to market. We have a very simple laboratory equiPanache Fashionsed with the basic research equipment we need. Ft. Presently our research is being supervised by our Technical team. However. We have thus far been able to discover lighter materials and several cost cutting manufacturing methods. now that we are becoming more experimental in our research efforts such a continued success ratio can not be maintained. 5+3.44+2+0.17 US$/UNIT TOTAL MANUFACTURING COST = 6.21+1.89 YEAR = 11 MONTH .5 US$ PROFIT @ 30 % PRICE = 3.17 = 9.= 0.2 = 14 US$ TARGET OUTPUT REVENUE/YEAR = 2500 UNIT/DAY = 2500x311x14 = 10885000 US$ PROFIT/YEAR = 1488000 US$ BREAK EVEN POINT = Total Fixed Cost/Profit Per Year =1322303/1488000 = 0.21 US$ SALES AND DISTRIBUTION COST = 1.2 US$ = 9.6+0.