Apparel Operations

A leading Management Consulting firm offering strategic advice, start up assistance, performance enhancement impetus, consumer insights and capital advisory, to leading Indian and International companies, operating in Retail & Consumer Products, Fashion (Textiles & Apparel), Healthcare, Food & Agriculture, Education and Leisure & Entertainment

A Leading Management Consulting Firm

Since our inception in 1992, as a Management Consulting firm across diverse industries, we have offered services to have far reaching impact on client businesses. Founded on the principle of concept to commissioning, we are strategic advisors to our clients during the ideation phase, implementation guides through start-up and a trusted advisor overall. Many of our projects come from repeat clients. Our team currently comprises 200+ skilled professionals from leading international and Indian engineering and management institutes. Most of our consultants have hands-on industry experience in their fields of specialization and represent a wide variety of functional backgrounds. This enormous knowledge and talent pool enables Technopak to create special customized teams for each project depending upon the client requirements. With a team of established domain experts at work, Technopak builds and enhances business capabilities for leading Indian and international companies by offering end-to-end solutions that are unique due to our rich experience, strong industry relationships and a global footprint.

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Many product you wear, eat, or carry has the touch of a Technopak consultant

Industry Segments We Serve - Apparel Operations

Apparel brands and retailers Garment Manufacturers & Exporters Apparel sourcing organizations Trade Promotion Councils & Industry Associations International Development Bodies & Financial Institutions Central & State Governments

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Services We Offer - Apparel Operations

Concept to Commissioning Start-up of apparel manufacturing business and plants, leveraging operations and industry expertise to commission the concept on a turnkey basis Planning and design of the factory Technology: Analysis, Recommendation and Induction Selection and training of middle management Implementation of layouts & process design Design and implementation of systems and procedures Efficiency and production build-up Performance Enhancement Leveraging techno-managerial expertise in apparel industry in enhancing performance of clients manufacturing facility Productivity / efficiency enhancement Process and Layout Engineering Quality improvement Reduction in lead time Material utilization improvement Supply chain improvement Streamlining pre-production and merchandising activities

Manufacturing Excellence Implementation of modern manufacturing concepts e.g. lean manufacturing, 6-sigma, with the goal of minimizing the amount of time & resources used in the manufacturing processes & other activities in clients business, with emphasis on eliminating all forms of wastages Lean Tools: 6S, 3M, Kaizen Lean Manufacturing Tools: SMED, Kanban, Heijunka, Poka Yoke, Jidoka, Andon, TPM inter alia. Toyota Sewing System Visual controls and SOPs Total Quality Management (TQM) DMAIC / DOE / SPC TOC (Theory of Constraints)

Skill Development Leveraging technical expertise for setting up training centre for operators based on scientific methodology and training & development of skills at different Levels Training of operators and trainers on AAMT methodology CSR Training for Middle Management Training of Middle Management and Line Supervisors on Master Plato Merchandisers, Quality Personnel and Industrial Engineers Training Training of HR on Compliance Requirements Soft-skill Training

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Our Focus
Performance Cost per SAM Efficiency Man to Machine Ratio Productivity per machine Quality DHU Repair Rate Cost of Quality Standard Operating Procedure Delivery On Time in Full (OTIF) Ship to Cut Ratio Lead Time Manufacturing Cycle Time Reduction CSR Employee Earnings Safety Health & Hygiene Society and Environment

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Technopak Events and Knowledge Partnerships

Technopak Leadership Forum(TLF) Organized by Technopak exclusively for CXOs to come together and discuss the direction for the Textiles and Apparel Industry.TLF is an annual event attended by more150 entrepreneurs and CXOs. World Apparel Convention Technopak was the knowledge partner with CMAI in an event that addressed leading brands and manufacturers from across the world.

Workshop Series 2009

TWS 2009-Apparel Operations

Apparel Workshops The workshop was aimed at discussing and brain storming steps that apparel manufacturers and exporters need to undertake in order to be globally competitive.

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Technopak Publications
Technopak Perspective | 2010 A report on how growth of value retailing, a global phenomenon now, has serious implications for Indian apparel and textile manufacturers.

Building Sustainable Businesses in the Growing Domestic Market | 2009 This paper highlights the vast opportunity that Indian domestic apparel market offers with the change in overall consumption patterns. 10 Questions That Seek Answers | 2009 The paper highlights why the T&A industry in India has lagged behind other industries in this growth and the answer to the 10 most pertinent questions that would allow us to realize the true potential of the T&A industry. Technopak-FICCI background paper; Indian Technical Textiles Industry | 2009 The paper focuses on the hindrances that are faced by the Technical Textiles industry and lays out the recommendations for the government and the industry.

Background Paper Indian Technical Textiles Industry

Our leadership team

Arvind Singhal Chairman & Managing Director arvind.singhal@technopak.com Arvind founded Technopak in 1991 and has led the company to be the thought leader in our sectors. Sharad Mehra Sr. Vice President sharad.mehra@technopak.com Sharad heads the fashion and apparel operations practice at Technopak. He has more than 15 years of strategy, business development and operations experience in apparel, textiles and accessories. Amit Gugnani Vice President amit.gugnani@technopak.com Amit possesses over 14 years of textile and apparel sector experience and has managed various projects involving entry strategies, business plan, feasibility studies, apparel plant startup, business process re-engineering etc. for leading national and international clients. Gautam Mukherjee Principal Consultant gautam.mukherjee@technopak.com Gautam has over 13 years of apparel sector experience working in senior management positions. At Technopak, he has worked on various projects involving apparel plant startup, business process re-engineering and skill development. Shalabh Srivastava Principal Consultant shalabh.srivastava@technopak.com Shalabh has over 11 years of experience in apparel sector and has worked with apparel firms at senior management positions. At Technopak, he has worked on various projects involving apparel plant start-up and business process reengineering. Sumit Pant Principal Consultant sumit.pant@technopak.com Sumit has over 10 years of experience in apparel sector and has worked with the major apparel firms. At Technopak, Sumit has worked on various projects involving business process re-engineering and apparel plant start-up. Ravi Katyayan Principal Consultant ravi.katyayan@technopak.com Ravi has over 10 years experience in Apparel Manufacturing. His key skills include Process, Project and Manufacturing Management with domain expertise in Apparel Operations, with on-the-ground experience in India and Nepal. Sanjeev Sharma Senior Consultant sanjeev.sharma@technopak.com Sanjeev has over 7 years of apparel sector experience working in senior management positions. At Technopak, he has worked on various apparel plant start-up, business process re-engineering, primary research and development projects.

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Samir Kumar Sinha Senior Consultant samir.sinha@technopak.com Samir has over 9 years of apparel sector experience working in senior management positions at various reputed companies in India. At Technopak, he has worked on various projects involving business plan, apparel plant start-up, business process re-engineering and lean implementation.

Representative Clients List

Branded Apparel Companies

Arvind Mills

Gloria Jeans

H&M

IKEA

ITC Limited

Madura Garments

Raymond Ltd

Reliance Industries

Study by Janak

Welspun

Manufacturers / Exporters / Buying House

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Babylon Garments Birla VXL Bombay Rayon Fashions Ltd Chandra Group Cornell Overseas Al-Karam Textiles Alok Industries Ambattur Clothing Ashima Group Ashton Apparels

Crystal Group

Emperor Trading

Esquel Group

Gokaldas Images

India Fashions

Integra Apparels

JCT Limited

Kapric Apparels

Lanka Equities

Leisure Textiles

Manufacturers / Exporters / Buying House

Lenny Fashions

MAS Holdings

Masood Textile Mills

Matrix Clothing

Meridian Apparels

MGK Impex

Mittal Clothing

Orient Craft

Primero Intimates

Priyadarshini Spinning

Sarita Handa

SCM Creations

SM Apparels

Shahi Exports

Stylecraft

Texport Garments

Texport Syndicate

Thiagarajar Mills

US Denim

Aditya Birla Group

There are some partnerships that are formed to create a global impact
Integra Apparels JCT Limited Kapric Apparels Lanka Equities Leisure Textiles
Government / Banking

Lenny Fashions

MAS Holdings

Masood Textile Mills

Matrix Clothing

Meridian Apparels

Case Study : Concept to Commissioning

Client is one of the largest vertically integrated in India. In its ongoing expansion drive, the company planned to set up a 1000 machine manufacturing plant and needed assistance in the setting up the factory.

Attained highest weekly efficiency of 38%

Trained 400 operators

29 Quality Checkers trained

70 helpers / line feeders trained

Implementation Process
Implementation of factory control system Process design and layout implementation Establishment of training centre for operator recruitment and training Implementation of direct incentive scheme for workers & middle management Selection & pre-training of middle management (including operator trainers) Implementation of Quality Assurance System

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16% 14% 10% 15% 21%

Sewing Efficiency %
38%

15% 12% 13%

16% 12%

18%

16

17

18

19

20

21 Weeks

22

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25

26

27

Client is a leading industrial group in Pakistan. As a part of its forward integration plans, they planned to set up a knit garment manufacturing facility with a monthly production capacity of 350,000 to 400,000 knit garments.

Case Study : Performance Enhancement

Client is a knit apparel manufacturing company based out of Faisalabad, Pakistan. The company with 3,000+ sewing machines, manufactures quality garments like t-shirt, polo shirt, jogging suit, henley shirt, raglan shirt, tank top, bikini, shorts, pants, sleepwear etc for mass and medium segment reputed buyers like Tommy Hilfiger, Tom Tailor, J.C.Penny, Levis, Dockers, Speedo, Abercrombie & Fitch, Champion, Nautica, Polo Ralph Lauren etc. Sewing Efficiency improved by 31% Monthly Sewing SAM produced increased by 15% Cutting Efficiency improved by 24% Fabric Utilization improved by 6.5% Reduction in monthly wastage (cutting room) by 18%

Operationalizing of first 250 machines in the factory

Achievement of average efficiency level of 51%

Achievement of DHU level of 8%

Implemented direct incentive scheme

Implementation Process
Complete planning and design of the factory Selection and implementation of state-of-the-art equipment, as appropriate for the local manufacturing conditions Implementation of effective manufacturing management procedures and engineering techniques Implementation of selection, training and placement procedures to assure skills necessary at production levels of the organisation in order to achieve and maintain competitive performance

Implementation Process
Implementation of Efficiency and Cost per SAM data as key performance measures Re-organization of Industrial Engineering practices Introduction of Warm Changeover Initiation of 6 days working 8 hrs per shift compared to 7 days working 11 hrs per shift Implementation of 5S Principles Process Flow Optimization Implementation of MPBU (Mobile Production Bundle Unit System) and proper Utilization of Switch Track System Implementation of Group Based Incentive System
Sewing Efficiency % 77% 67% 59% 51% 54% 46% 68% 74% 58% 47% 52% 58% Cutting Efficiency %

Sewing Efficiency %
49% 50% 51% 51%

41% 35% 34% 32% 36% 38%

43%

45% 45% 41%

44%

46% 47%

32% 27% 23% 18% 15% 9% 5% 22% 29% 26%

25

26

27

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32

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34

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37

38 Weeks

39

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51
Unit 1 Unit 2 Before Re-engineering Unit 3 After Re-engineering Unit 4 May'09 Aug'09 Sep'09 Oct'09

Client is a leading apparel manufacturer-exporter based out of Chennai. Client had approached Technopak to assess its manufacturing units and undertake re-engineering exercise for the existing facilities by implementing effective manufacturing management procedures and engineering techniques to improve performance levels.

Case Study : Manufacturing Excellence

Client is a denim bottom manufacturing facility located in Bangalore.

Sewing Efficiency improved by 26%

Monthly Sewing SAM produced increased by 12%

Reduction in Style Chnageover Time from 480 mins to 135 mins

Streamlined maintenance department

Efficiency improvement from 24% to 46%

Reduction of defectives by 40%

Monthly SAM produced increased by 38%

Style changeover time reduced from 540 to 180 minutes

Implementation Process
Effective implementation of Mobile Progressive Bundle System across factory Training program for supervisors, Quality Checkers and floor in charge awareness about latest sewing techniques Streamlined pre production process by introducing Style Reviews & Sampling Procedures, better coordination between pattern making, cutting, CAD & sewing Effective implementation of Time and Action calendar, sampling plans, pre-production meetings, PPMC follow ups

Implementation Process
Loss controlled during Shift changeovers by implementation of SMED (Single Minute Exchange of Dyes) Re-training of Industrial Engineering department Application of DOE (Design of Experiments) / DMAIC (Define, Measure, Analyse, Improve and Control) to improve specific operations Training program conducted to assure skills necessary at production levels to achieve and maintain competitive performance

Monthly Efficiency Analysis

Sewing Efficiency %
54% 43%

Style Changover Time

480 Mins

50 45 40 Efficiency 35 30 25 29% 24% 35% 34% 38% 35% 41% 42% 46%

135 Mins

20 15

Before Re-engineering

After Re-engineering

Before Re-engineering

After Re-engineering

Oct07

Nov07

Dec07

Jan08

Feb 08 Months

Mar08

Apr08

May08

Jun08

GTZ is an international cooperation enterprise for sustainable development with worldwide operations. Implementation Process
Factories started measuring DEFECTS as compared to DEFECTIVES, earlier Statistical Process Control had been implemented in 7 organizations Defined Standard Operating Procedures (Quality SOPs) Defect Taxonomy created for better visibility and understanding Problem solving tools to reduce the re-occurrence of defects Concept of 5S implemented Visual Controls in place
Sewing ending DHU improvment % over baseline 60 Defected per hundred units 50 40 30 20 10 0 Columbia Comfort Wear Mavis Bangla Pashak Golden Horizon Best Wool Pinkai Onus Bando Pretty Well Fashions Deluxe Fashion Jamuna 18 11 12 18 19 32 39 40 44 44 45 46 56

Case Study : Manufacturing Excellence

UNDP is the UNs global development network, advocating for change and connecting countries to knowledge, experience and resources to help people build a better life. UNDP Islamabad initiated the Project Gen-Prom, Pakistan with the objective to alleviate poverty by creating , employment opportunities for the women in Pakistan. Implementation Process
Develop clear team structure, organization, and recruitment criteria by inviting applications, short listing of candidates and conducting tests and interviews Selection and Training of Program Coordinators, Master Trainers and female operators through class room and sewing sessions simultaneously. Provided Best Practices guidelines to Participating Companies

Results
To summarize the achievement, while 12 Program coordinators, 266 Master Trainers and ~ 1,400 Workers (out of which 1,251 were female operators) have been trained directly across Faisalabad, Lahore and Karachi, ~3500 operators (90% females) have been trained in Satellite Training Units established by Technopak.

The Skills for Employment in Apparel Manufacturing (SEAM) is a special project under Swaranjayanti Gram Swarojgar Yojana (SGSY) scheme funded by Ministry of Rural Development (MoRD), Government of India with the aim of creation of gainful employment in Apparel Industry Implementation Process
Identifying the BPL regions across India and Selection of BPL youth operators Selection of participating factory willing to directly recruit and train BPL candidates Training of the selected BPL youth to the requirements of the companies on AAMT Methodology Ensuring a healthy transition of the trained BPL youth into the production lines of the factorys Follow up on the performance of the BPL youth in the factorys

Participating Factories

Results
Generating employment for rural BPL youth Reducing poverty giving livelihoods Training- high on quality, low on cost Set-up In-house Training Center for future sustainability

Sewing ending DHU improvment % over baseline 80 Repair Percentage 70 60 50 40 30 20 10 0 3% Columbia Comfort Wear Mavis Bangla Pashak Golden Horizon Best Wool Pinkai Onus Bando Pretty Well Fashions Deluxe Fashion 14% 30% 21% 16% 36% 37% 30% 50% 45% 46 75%

Participating Factories

Services we offer through our Group Companies

B u i l d i n g

T o m o r r o w

Planning, implementation and project management of plants, warehouses and entertainment centers with a focus on modernization, process improvement, technical valuation, power & water audit and environmental engineering. www.arvana.in

Strategizing, planning and managing creation, development and growth of brands through a scientific, transparent and process-driven methodology. www.vertebrand.com

Financial Advisory Services

Technopak Financial Advisory Services (TFAS) is the financial and transaction advisory services arm of Technopak . With its team of experienced transaction professionals located in India and across US and Europe; TFAS offers its clients a global transaction ability, deep understanding of its industries of focus, and an efficient negotiating platform for stakeholders. www.technopak.com/tfas

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Insights and innovation led product, packaging, space and strategic design, including design research, concepts, engineering and prototyping. A blend of unique, contemporary and relevant concepts and solutions. www.foleydesigns.com

Technopak Advisors Pvt. Ltd. Gurgaon - Head Office 4th Floor, Tower A, Building 8, DLF Cyber City, Phase II, Gurgaon 122 002 (National Capital Territory of Delhi), India T: +91-124-454 1111, F: +91-124-454 1198

Website: www.technopak.com