3.5WORKFLOW OF THE FINISHING DEPARTMENT
Kaj / Button marking (manually) Kaj / Button marking (manually) Receive goods from sewing Receive goods from sewing
Bartacking Bartacking
Button hole stitching Button hole stitching
Washing Washing
Button attaching Button attaching
Thread Cutting Thread Cutting
Thread suctioning Thread suctioning
Ironing Ironing
Initial Checking Initial Checking
Alteration (if any) Alteration (if any)
Quality Audit Quality Audit Measurement check (10%) Measurement check (10%)
Final checking Final checking
Re-pressing Re-pressing
Shade matching Shade matching
Folding and putting in poly bags Folding and putting in poly bags
Tagging Tagging
Dispatching to packing section Dispatching to packing section
Erudition:
Erudition:
Finishing is one of the most important departments where the final appearance of theFinishing is one of the most important departments where the final appearance of the garment is achieved.
garment is achieved.
Loose threads are deterrent to businessLoose threads are deterrent to business
It is better to remove as many unwanted threads aIt is better to remove as many unwanted threads at the sewing stage as possiblet the sewing stage as possible
Proper carton packing needs to be done for avoiding problems in shippingProper carton packing needs to be done for avoiding problems in shipping
36
Vertical IntegrationVertical Integration
Specialized unitsSpecialized units
Quality adherenceQuality adherence
Introduction of ERPIntroduction of ERP
Efficient planning DepartmentEfficient planning Department
Weakness Weakness
Centralized cuttingCentralized cutting
Technological AdvancementTechnological Advancement
Centralized MerchandisingCentralized Merchandising
Inefficient use of ERPInefficient use of ERP
Communication gaps between teamCommunication gaps between team members
members
Lack of team workLack of team work
Opportunity Opportunity
Incentives and support fromIncentives and support from
government for export oriented units.
government for export oriented units.
International presenceInternational presence
Low labor cost comparing to buyingLow labor cost comparing to buying countries
countries
Threat Threat
International CompetitionInternational Competition
1.
1. STRENGTHSTRENGTH::
VERTICAL INTEGRATION
VERTICAL INTEGRATION: : Shahi Export House Company Shahi Export House Company started its operatstarted its operation way back inion way back in 1973. Earlier established in Delhi ( Okhla), now in Faridabad, Shahi stands vertically integrated 1973. Earlier established in Delhi ( Okhla), now in Faridabad, Shahi stands vertically integrated as one of the largest manufacturer/exporters in India offering ready-to-wear garments for ladies, as one of the largest manufacturer/exporters in India offering ready-to-wear garments for ladies, men and children. It
men and children. It consists of
consists of units including the areas units including the areas of Noida, Ranjitnagar, Gaziabad and in of Noida, Ranjitnagar, Gaziabad and in Bangalore. ThoughBangalore. Though all the units are in different areas of Delhi & surrounding areas, there is a smooth flow of work all the units are in different areas of Delhi & surrounding areas, there is a smooth flow of work between
between all the all the units. units. In total In total there there are 18 are 18 integrated state-of-the integrated state-of-the art art garment production garment production centerscenters of Shahi. It has its own integrated unit of fabric mills, processing units, printing & dyeing, of Shahi. It has its own integrated unit of fabric mills, processing units, printing & dyeing, embroidery, wash & finishes.
embroidery, wash & finishes.
In the case of fabric capability Shahi ha In the case of fabric capability Shahi has:s:
Integrated fabric base for both wovens and Integrated fabric base for both wovens and knits.knits.
Both facilities equipped with German and Swiss state of the art processing MachinesBoth facilities equipped with German and Swiss state of the art processing Machines which ensures a high level quality output
which ensures a high level quality output
Sourcing office in China providing access to diveSourcing office in China providing access to diverse fabric bases in the Far Eastrse fabric bases in the Far East
Sourcing relationship with all leading mills in India like Arvind, Morarjee, Ashima,Sourcing relationship with all leading mills in India like Arvind, Morarjee, Ashima, Vardhman and several independents in auto-loom
Vardhman and several independents in auto-loom sector.sector.
Sarla Fabrics
Sarla Fabrics (Earlier called as Palmprint Textiles), the fabric process house is one of India’s(Earlier called as Palmprint Textiles), the fabric process house is one of India’s foremost wet processing plant. All kinds of woven fabrics like poplin, twill, canvas, gauge, foremost wet processing plant. All kinds of woven fabrics like poplin, twill, canvas, gauge, corduroy, chiffon, moss crepe, Rayon, Georgettes, Nets, Velvets, Cambric, satin, Bosky, lycra corduroy, chiffon, moss crepe, Rayon, Georgettes, Nets, Velvets, Cambric, satin, Bosky, lycra etc are processed to international standards.
etc are processed to international standards.
Prints like reactive, vat colour discharge on reactive grounds & pigments apart from some Prints like reactive, vat colour discharge on reactive grounds & pigments apart from some special printing techniques like burnt out effects on polyester-cotton blends are achieved here. In special printing techniques like burnt out effects on polyester-cotton blends are achieved here. In all, the unit
all, the unit produces about produces about 90,000 mtrs of 90,000 mtrs of processed fabric processed fabric per day.per day.
This puts Shahi at the top compared to the other export house. It cuts down the lead-time &
This puts Shahi at the top compared to the other export house. It cuts down the lead-time &
prices.
prices.
Consistency: when a company is vertically integrated there is a lot of consistency in theConsistency: when a company is vertically integrated there is a lot of consistency in the fabric. As from the yarn stage to the weaving stage medium remains one. Therefore there fabric. As from the yarn stage to the weaving stage medium remains one. Therefore there is no involvement from outside. It eliminates the mediators, excluding the provisions of is no involvement from outside. It eliminates the mediators, excluding the provisions of wastages, transportation costs etc.
wastages, transportation costs etc.
Lead times: when every procedure is done under one roof, it abolishes the time requiredLead times: when every procedure is done under one roof, it abolishes the time required to transport the material from one place to another.
to transport the material from one place to another.
38 38
Reduced transportation cost: transporting a product from one place to another consumesReduced transportation cost: transporting a product from one place to another consumes time & money. For any value added service like washes, sequins a company send the time & money. For any value added service like washes, sequins a company send the fabric or garment to other locations but this is not a case with Shahi every thing is done in fabric or garment to other locations but this is not a case with Shahi every thing is done in house thus reducing transportation cost.
house thus reducing transportation cost.
Specialized units
Specialized units: Shahi has divided the Faridabad & Bangalore as woven & knits unit: Shahi has divided the Faridabad & Bangalore as woven & knits unit respectively. By making the units specialized it has help the company in achieving better &
respectively. By making the units specialized it has help the company in achieving better &
faster production. As the same work is repeated again, it helps staff to understand faster & better faster production. As the same work is repeated again, it helps staff to understand faster & better which has lead to efficient utilization of resources & quality shipments.
which has lead to efficient utilization of resources & quality shipments.
QUALITY ADHERENCE
QUALITY ADHERENCE: Shahi relates itself with quality. Quality department places checks: Shahi relates itself with quality. Quality department places checks at all the required areas in all the production departments like, fabric department, cutting at all the required areas in all the production departments like, fabric department, cutting department, sewing department, finishing & packaging department. Other than this Q.A’s are department, sewing department, finishing & packaging department. Other than this Q.A’s are also allotted for each specific brand within the organization. The Q.A department also takes also allotted for each specific brand within the organization. The Q.A department also takes active part in the sampling as it is the
active part in the sampling as it is the base on which order comes.base on which order comes.
Focus on quality and a proven track record Focus on quality and a proven track record
↔
↔ Short shipment : 0.50%Short shipment : 0.50%
↔
↔ On time delivery : 98%On time delivery : 98%
↔
↔ Quality claims: Nil.Quality claims: Nil.
INTRODUCTION OF ERP
INTRODUCTION OF ERP – – M3 M3
The whole computerization system helps keep all the departments in link with each other. The The whole computerization system helps keep all the departments in link with each other. The software used is used for almost every function &
software used is used for almost every function &
process-
SamplingSampling
CostingCosting
Order capturing (job order details, fabric, trims requirements)Order capturing (job order details, fabric, trims requirements)
Production (Cutting, stitching, finishing, packing, consignment delivery)Production (Cutting, stitching, finishing, packing, consignment delivery)
Shipment (boxes, box no., place)Shipment (boxes, box no., place)
Buyer’s PO entry (Invoicing & Billing)Buyer’s PO entry (Invoicing & Billing)
Accounts/Finance (interlinking of bills, vouchers, payments, salary management, variousAccounts/Finance (interlinking of bills, vouchers, payments, salary management, various allowances)
allowances)
Time Management (leave records, calculation of boTime Management (leave records, calculation of bonus, reimbursement amount etc)nus, reimbursement amount etc) The top management people can keep track of the status of production just by a single click. All The top management people can keep track of the status of production just by a single click. All departments can keep in touch with each other and can know the status of orders.
departments can keep in touch with each other and can know the status of orders.
Without this whole computerization system it would had been difficult for various departments Without this whole computerization system it would had been difficult for various departments to interlink with each other.
to interlink with each other.
EFFECIENT PLANNING DEPARTMENT
EFFECIENT PLANNING DEPARTMENT - the planning department of the company has a- the planning department of the company has a very good team of members which very carefully studies each garment. After the complete very good team of members which very carefully studies each garment. After the complete analytical study of each garment the
analytical study of each garment the team makes different combinations of folders & team makes different combinations of folders & attachmentsattachments in such a manner that it helps in faster & efficient production that too with minimal wastage of in such a manner that it helps in faster & efficient production that too with minimal wastage of time.
time.
2.
2. WEAKNESSWEAKNESS
CENTRALIZED CUTTING :
CENTRALIZED CUTTING : there is a centralized cutting in the head unit. Cutting for Delhithere is a centralized cutting in the head unit. Cutting for Delhi NCR their order, in turn wasting the time and d
their order, in turn wasting the time and delay in the production.elay in the production.
TECHNOLOGY:
TECHNOLOGY: machines that are being used in the organization in the sewing departmentmachines that are being used in the organization in the sewing department even
even in the cutting in the cutting department automatic sdepartment automatic spreader and cutting preader and cutting machines are very old machines are very old and needand need updation. Investment in the machinery is less.
updation. Investment in the machinery is less.
TIME CONSUMPTION IN THE FINISHING DEPARTMENT (SAMPLING) TIME CONSUMPTION IN THE FINISHING DEPARTMENT (SAMPLING) : :
The sampling in Shahi has to go within 3 days of receiving the tech pack. The pattern making, The sampling in Shahi has to go within 3 days of receiving the tech pack. The pattern making, cutting & stitching is done within 2 days but the finishing department takes more than 1 day to cutting & stitching is done within 2 days but the finishing department takes more than 1 day to finish a garment. This at times becomes a messy situation. As the sampling department is too big finish a garment. This at times becomes a messy situation. As the sampling department is too big the finishing department & the workers are less compared thus a merchant has to always be the finishing department & the workers are less compared thus a merchant has to always be
40 taken care by the merchants in the Faridabad unit. At times it becomes too messy to track one taken care by the merchants in the Faridabad unit. At times it becomes too messy to track one order as the merchant is sitting in Faridabad and giving instructions at Bangalore. This creates order as the merchant is sitting in Faridabad and giving instructions at Bangalore. This creates confusion as the merchant in Faridabad is not aware of what is going in Bangalore. This confusion as the merchant in Faridabad is not aware of what is going in Bangalore. This eventually increases the lead time as everything has to be sent to Faridabad merchants for eventually increases the lead time as everything has to be sent to Faridabad merchants for approval and then sent back. As the lot approval has to be sent to Faridabad after the approval it approval and then sent back. As the lot approval has to be sent to Faridabad after the approval it is again sent to the production unit, this activity is very time consuming. Even the P.O. is made is again sent to the production unit, this activity is very time consuming. Even the P.O. is made by
by the the merchant merchant in in Faridabad Faridabad so so if if there there is is some some shortage shortage of of fabric fabric it it has has to to be be informed informed inin Faridabad after which again a
Faridabad after which again a P.O is raised after which only the fabric is genP.O is raised after which only the fabric is generated.erated.
INEFFICIENT USE OF ERP: order, but this is not done. The system is used just to generate the P.O which is a part of the ERP.
order, but this is not done. The system is used just to generate the P.O which is a part of the ERP.
The merchandisers have not taken any classes for the same; they are working on hit & trial The merchandisers have not taken any classes for the same; they are working on hit & trial method or learnt something from their seniors.
method or learnt something from their seniors.
3.
3. THREATSTHREATS
1)
1) International competitionInternational competition
China, which is the largest exporter, has substantially increased its market share. Countries China, which is the largest exporter, has substantially increased its market share. Countries like Bangladesh and turkey are very cost effective. China excels in the industry because of like Bangladesh and turkey are very cost effective. China excels in the industry because of cheap labor, efficient management, higher productivity, government policies, strong research cheap labor, efficient management, higher productivity, government policies, strong research and development and industrial base.
and development and industrial base.
4.
4. OPPORTUNITIESOPPORTUNITIES 1)
1) Incentives and support from government for export oriented units:Incentives and support from government for export oriented units:
The government pays duty-drawback i.e. you get the excise duty and import duty back.
The government pays duty-drawback i.e. you get the excise duty and import duty back.
2)
2) International presence :International presence :
SHAHI has a international presence in the
SHAHI has a international presence in the global market. It is well-renowned for its quality andglobal market. It is well-renowned for its quality and facilities. It is one of the leading exporters of appa
facilities. It is one of the leading exporters of apparel.rel.
42 42