buss plan(1)
TRANSCRIPT
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A A S S S S I I G G N N M M E E N N T T T T H H E E M M E E ::
D D E E T T A A I I L L E E D D P P R R OO J J E E C C T T R R E E P P OO R R T T ( ( D D P P R R ) )
R R E E A A D D Y Y M M A A D D E E G G A A R R M M E E N N T T S S ( ( R R M M G G ) )
S S U U B B M M I I T T T T E E D D B B Y Y ::
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A A mm r r ii t t aa J J ( ( 2 2 3 3 ) )
J J yy oo t t ss nn aa N N ( ( 3 3 88 ) )
M M aa nn ii ss hh V V ( ( 5 5 7 7 ) )
K K aa vv ii t t aa T T ( ( 5 5 5 5 ) )
S S U U B B M M I I T T T T E E D D T T OO ::
P P r r oo f f .. B B hh aa vv nn aa mm aa mm
S S U U B B M M I I S S S S I I OO N N D D A A T T E E ::
1 166 t t hh M M aa r r cc hh ,, 2 2 0 0 11 11
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-- GG EE NN TT SS R R EE AA DD YY MM AA DD EE GG AA R R MM EE NN TT SS
II NN TT R R OO DDUU CC TT II OO NN::
Readymade garment industry has occupied a unique place in the industrial scenario of our
country by generating substantial export earnings and creating lot of employment. Its
contribution to industrial production, employment and export earnings is very significant.
This industry provides one of the basic necessities of life. The employment provided by it is a
source of livelihood for millions of people. It also provides maximum employment with
minimum capital investment. Since this industry is highly labour-intensive, it is ideally suited
to Indian condition. This project report is prepared for the manufacture of gents shirts, gents
trousers as they find wide acceptance in local and international markets. Such establishments
can be easily set up by any person having the knowledge of cutting and stitching operations.
MM AA R R K K EE TT PP OO TT EE NN TT II AALL ::
Readymade garments are the choice of urban people. It is also gaining wider acceptance in
semi urban and rural areas. The huge charges made by tailors and delay in delivery have
made people to switch over to readymade garments. In domestic market and export market, it
has made spectacular progress in the last decade. This industry is becoming very vibrant and
lot of foreign investment pouring in this industry because of low risk and high earning nature
of this industry. As these products are fashion oriented, entrepreneurs should always keep in
mind the changing fashion styles. Considering its advantageous position, it is assumed that
there will be no constraint in marketing of gents readymade garments.
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SSII TT EE II NN VV EE SSTT II GG AA TT II OO NN BBAA NN GG AA LL OO R R EE
R R EE AA DDYY MM AADD EE GG AAR R MM EE NNTT SS IINN DD UUSSTT R R YY IINN PP EE R R SSPP EE CC TT II VV EE
AANN DD II TT SS PP R R EE SSEE NN TT SSCC EE NNAA R R IIOO II NN TT HH EE SSTT AA TT EE .. The garment industries in the State are concentrated in Bangalore where some of the largest
export houses of the country are existing. Today overseas buyers view Bangalore as an
important location for sourcing of garments after Bombay and Delhi. Brand images are being
felt in this region and there is a great potential for production of value added goods. Ready
made garment industries are also concentrated in Bellary district. The units in Bellary are
specialized in manufacture of jeans and other leg wears for men. The next place of
concentration of this industry is Shimoga district followed by Dharwad district as per the
information furnished by the Directorate of Industries and Commerce. There is also a
concentration of hosiery industry in Belgaum. The district wise distribution of registered
readymade garment units in SSI sector in the State is given below:
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(Source: Directorate of Industries and Commerce, Govt. of Karnataka, Bangalore)
Field studies have showed that there are approximately 40,000 readymade garment-
manufacturing units in India. Around three five million people are working in the industry.
Many leading world fashion labels are being associated with Indian products. India is being
looked upon as a major supplier of high quality fashion apparels, which are being appreciated
in major international markets. The credit for this goes to our garment exporters. However,
till today our clothing industry is dominated by subcontracting and consists mainly of small
units with a few machines of medium quality, relatively high fashion, but small volume
business. Thus the need of the hour is to enlarge both manufacturing as well as the marketing
base. Tapping new markets especially Central Africa CIS, East European Countries, Latin
America, Australia and I South Africa is also essential for growth and development of Indian
garment industry.
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DDEE SSCC R R II PP TT II OO NN OO FF TT HH EE CC LL UU SSTT EE R R
Garment industries in Bangalore started from the period of British. M/s. Bangalore
dressmaking Co. was the first unit, started to manufacture garment in Bangalore during 1940,
which was started by Mr. Vittal Rao. During the rule of British, there was a need of clothing
dress materials. This led to the development of R.M.G industries in Bangalore. Apart from
RMG industries, there were silk weaving industries in Bangalore, which led to the
development of silk exporters also. After Indias independence in 1947, the industries started
picking up slowly to cater the needs of dresses of the common man and local market. The
industry started flourishing. Most of RMG industries are concentrated in Bommanahalli and
Peenya industrial estate. After the dereservation of garments, big players like Mafthlal,
Aravind Mills, etc. started entering the field and occupied places in the sector which
indirectly effected the small scale sector. There are about 2500 RMG units in and around
Bangalore. Most of the buying agencies in the world have established their branch office in
the city. Apart from this, Apparel Park, at Doddaballapur has started functioning in a big
way. Some of the leading exporters like Gokaldas Images, Raymond, Pooja garments, have
already taken the plot for their units in the apparel park. There are 28 garment units including
processing industries have taken the plots. This has contributed in a big way to the
development of clusters of RMG industry. In India, RMG units are concentrated in the cities
like Delhi, Mumbai, Kolkotta, Bangalore, Chennai, Jaipur, Tirupur, Ludhiana. There is a
different in the end products manufactured at Bangalore and other places. RMG are mainly
made for export house. There are many SSI units mainly doing job work providing supports
to the SME like GE, Aravind fashion, Sonal Holding, Texport Syndicate units in the cluster.
The technology and manufacturing process are same as used in other regions.
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BBR R OO AADD PP R R OO DD UU CC TT GG R R OO UU PP II NNGG
In Bangalore, garment units are mainly concentrated in the following area
1. Bommanahalli
2. Bommasandra
3. Peenya
4. Yeswanthpur
5. Rajajinagar Indl Estate and Industrial town
PP rr oodd uu cc tt ss:: --
LL aa dd iieess
i. Jacket
ii. Blouses
iii. Chooridar
iv. Petticoats
GG eenn tt ss::
i. Trousers
ii. Shirts
iii. Coatsiv. T Shirts
RMG units in Bangalore are mainly manufacturing ladies/gents dresses, kids
sweaters are normally received from other cities like Kolkotta, Delhi, Indoor etc.
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CC UU R R R R EE NN TT OO UU TT PP UUTT
There has been increase in the number of RMG units in Bangalore since 1990. At present
there are about 800 active readymade garment manufacturers and exporters, still number is
likely to increase as per the reports of apparel park at Doddaballapur, near to Bangalore.
Karnataka Industrial Area Development Board is in the process of acquiring SISI Bangalore 8
the lands for the further expansion of the park. There are about 1600 fabricators who are
doing job work for these exporters, apart from domestic market needs. There are 50
embroidery units who are supporting these units for value addition. As per the reports
received from AEPC, total export upto December was around Rs.3050 Crores.
Total output from this cluster is about 3500 crores of which about 3000 crores are exported
and rest are consumed in the domestic market. Broad sub grouping of the products is as
follows:
1. Readymade garments for Gents, : 60%
2. RMG for ladies : 30%
3. RMG for kids : 10%
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FF AA CC TT OO R R SS II NN CC OO NNSSII DDEE R R AA TT II OO NN
GG eeooggrr aa pp hh iiccaa ll II nn dd iiccaa tt iioonn
Development of RMG units in Bangalore was started in the year 1970 onwards by leadingexporters like Gokaldas export, Ashoka export, Gokadas Images, continental exports, Leela
Fashions etc. Later, small industries (fabricators) were started by taking the orders from large
scale. Most important reasons for developments of RMG is the availability and sourcing of
export fabrics from places like Salem, Erode, Coimbatore which are nearest to Bangalore
(About 5 to 7 hours journey). The other reasons, which contributed for the development of
industries, are also as follows:
AA vvaa iillaa bb iilliitt yy oof f sspp aa ccee:- Space is no bar around Bangalore for the development of
industries. There are 10 industrial estate developed by KSSIDC. KIADB is also providing the
necessary support by giving plots to the industries for construction. Apart from this there are
private industrial estates, which are supporting the growth of industries, and further garment
complex has been constructed at Rajajinagar exclusively for garment industries. Land and
sheds are available in Bommanahalli and in and around peenya.
AA vvaa iillaa bb iilliitt yy oof f rr aa ww mm aa tt eerr iiaa ll :: - Fabrics, which are required for these industries are
available from Salem, Erode, Chennai, Mumbai, and Ahmedabad and also from local
suppliers (Agents). There is no problem in this area, which is helping the industries in a SISI
Bangalore great way. There is no weaving or spinning mills in and around Bangalore. Hence
all the exporters are sourcing fabrics from other places, as said above.
SS k k iilllleedd llaa bb oouu rr : - Low-income group of family adopted tailoring as the main source of
income for their livelihood. Tailors were abundantly available in the city. Some of the leading
training institutes also helped in this area by contributing (trained) skilled labours. This is themain factor that led to growth of this industry. But recently during the visits it is found that
there is severe scarcity of skilled labours and machine operators, which has effected
production schedule heavily. This has to be taken up very urgently to avoid the cancellation
of export orders as suggested by the units.
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EE xxiisstt eenn ccee oof f aa iirr pp oorr tt //ccaa rr ggoo ccoonn tt aa iinn eerr dd eepp oott //iinn f f rr aa sstt rr uu cc tt uu rr ee:: --
Bangalore being the Silicon valley of India have all the facilities of handling passengers and
presence of cargo container department further facilitated the growth of the cluster. Presence
of high way NH-4 and 7, ring road connecting the industrial estates, road transportation
within the city facilitated the growth of the industries. One of the most important factors is
the proximity of Chennai Port/international airport to this city. This helped a lot to the
industries for transporting the goods quickly. This has really contributed in flourishing the
export import business not only for RMG Enterprises but also for those involved in other
trades. Union Ministry of state for Road Transports and highways has announced that
construction of four lane elevated expressway between Bangalore and electronic city will be
commenced during current financial year. This will further add support for the exporters for
quick movement of goods. Apart from this international airport is in
progress at Devenahalli, near to Bangalore (30Kms).
FF llee xxiibb llee sspp eecciiaa lliizzaa tt iioonn :: --
The entrepreneurs in the cluster are capable of manufacturing wide range of garments with
different designs, different materials, different sizes etc. Subcontracting arrangements have
made the manufacturing more flexible and specialized. The cluster can handle huge orders.
Most of the buyers in the world have their branch offices in the city. Entrepreneurs can easily
approach them for suggestions and advice. This is most important in terms of time anddelivery.
EE nn tt rr eepp rr ee nn eeuu rr sshh iipp :: --
Bangalore is well known for these enterprises. Since Bangalore is a metropolitan city and no
language barrier. It is also noticed that most of the owners of the garment industries are from
North India. Officers and skilled workers are local and some SISI Bangalore of them are from
neighboring states. Growth of these industries resulted due to weather condition of the city,
which was pleasant and cool. As a result most of the industrialist from North settled in
Bangalore and established RMG units. Apart from these, leading textile mill manufacturers
opened dealers/trader for supplying fabrics like Century Mills, Aravind mills, Nahar mills
etc. All these have contributed for the emergence and growth of RMG clusters in Bangalore.
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BB AASS II SS AANNDD PP R R EE SSUU MM PP TT II OO NN SS ((OO VVEE R R AA LL LL PP R R OO JJ EE CC TT ))
1. This project is based on single shift basis and 300 working days in a year.
2. Since this industry is labour intensive, the working efficiency is considered at 75%.
3. Costs of machinery and equipment/material indicated refer to a particular make and
approximately to those prevailing at the time of preparation of this project.
4. Installation and electrification cost is taken @ 10% of cost of machinery and equipment.
5. Non-refundable deposits, project report cost, trial production, security deposits with
Electricity Board are taken under preoperative expenses.
6. Depreciation has been considered:
(a) On Building @ 5%
( b) On plant and machinery @ 10%
(c) On office furniture and fixtures @ 15%(d) On other fixed assets @ 15%.
7. Interest on capital investment has been taken @ 14% per annum.
8. Minimum 25% of total investment is required as margin money.
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Implementation period in months for executing
this project in stage-wise is given in the table.
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TT EE CC HH NN II CC AA LL AA SSPP EE CC TT SS
PP R R OO CC EE SSSS OO FF MM AA NNUU FF AACC TT UU R R EE ::
The process involves the following steps:
Procurement of Fabric : Dyed/ bleached/printed cotton/synthetic fabrics as per demand are
to be procured from the open market. The fabric will be inspected by laying on the inspection
table against light before cutting so that unevenness in colour/ shade or any other fault, if any
visible in the fabric are eliminated.
Cutting and Stitching : The inspected fabric is placed on the cutting table in layers and
then the different parts of the respective garments are demarked by a chalk as per differentsizes. Cutting is carried out by the cutting machine. Stitching is carried out for individual
portion of the garments by skilled workers with the help of overlock, lock stitch machines
etc.
W ashing, Checking, Pressing and Packing: All garments are charged into washing
machine containing mild detergent and washed for 4 hours in order to remove dirt and stains
acquired during the manufacturing process. After washing, the garments are hydroextracted
to remove excess water and after this, these garments are dried in tumbler dryer. Final
checking is done before pressing and packing on the checking table so that any fault in the
piece may be removed and protruding threads eliminated. The individual pieces are pressed
by steam presses to remove any wrinkle marks and packed in the carton boxes.
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The quality of garments mainly depends on quality of fabric used. Therefore, care must be
taken while purchasing fabrics to ensure good colour fastness properties, uniformity in shade
etc. Generally garments are made as per customers specification in respect of size, design
and fashion.
MM oott iivvee PP ooww eerr
Total 55.5 HP is required to run this unit at installed capacity.
PP oolllluu tt iioonn CC oonn tt rr ooll
The process of manufacture does not generate pollution. However, entrepreneurs are to
contact State Pollution Control Board for necessary guidance.
EE nn eerr ggyy CC oonn sseerr vvaa tt iioonn
Maximum care should be taken while selecting the machinery and other electrical equipments
so as to ensure minimum power consumption.
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FF II NN AA NN CC II AA LL AA SSPP EE CC TT SS
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1. M/s. Paras Special Machine Co.
Madhopur Kucha No. 7,
Rohan Road, Ludhiana.
2. M/s. Vijay Sewing (P) Ltd.
17-D, Everest House,
46-C, Chowringhee Road, Kolkata.
3. M/s. Industrial Machines Pvt. Ltd.
1/23 B, Asaf Ali Road, New Delhi-2
4. M/s. Apparel and leather
Techniques Pvt. Ltd.
Kaikondanahalli,Sarjapur Road,
Near Bellaandur Gate, Bangalore-35.
5. M/s. Industrial Sewing Systems
30, Ramakrishna Street, North
Usman Road, T. Nagar, Chennai.
R R AA WW MM AA TT EE R R II AALL SS UU PP PP LL II EE R R SS
1. M/s. Vardhman Threads
Mahavir Spinning Mills Ltd.
Chandigarh Road,
Ludhiana-141001.
2. M/s. Powerloom Cloth
Manufacturing Centre
Erode, Bhiwandi, Mumbai, Surat etc.