PEARL ACADEMY

DEPARTMENT OF FASHION

MERCHANDISING

“LEAD TIME COMPRESSION”

Submitted by:

Mohd Ubaid

(2014 - 2016)

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started in 2009 at New Delhi.

initially, it was an export house.

caters buyers from USA, UK and RUSSIA.

Emphasis is placed on:

1. Sourcing Efficiently

2. Cost Effectively

3. Delivering Quality Products On Time

INTRODUCTION TO

“Kolor Koncepts”

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Objective :To satisfy the business needs of our clients efficiently adding value

and enhancing profitability at all times

MISSION STATEMENT :In today’s changing business dynamics it’s important to have

speed/quality/flexibility

KOLOR KONCEPTS

MENS WOMENS KIDS

APPARELS

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BUYERS

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VENDOR

• Unique collection

• Sam apparels

• Certitude

• vishesh apparels

• shorshots

• kalamakri

•Textline Apparel

• Maya Exports

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DIRECTOR

PRODUCTION MANAGER

QUALITY CONTROL

MERCHANDISER

SAMPLING

FINISHING

PRODUCTION MANAGER

MERCHANDISER

QUALITY CONTROL

ACCOUNTS

BOOKING DEPT.

Organization structure

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SWOT

S-Strength

•Emphasizes and values its consumers the most.

•It lays stress on long term relations and therefore has avery strong customer loyalty.

•They try and adopt a process which is full of research,innovation, tested and tried that best serves thecustomers..

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SWOT

W-Weakness

•Lack of skilled employees

•Lack of management, departments

•Remote location.

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SWOT

O-Opportunities

•As the retail market is growing, therefore more buyers

in future.

• has great opportunities to diversify itself into fields

such as accessories and footwear which is important to

expand business

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SWOT

T-Threats

•Large number of buying houses in Delhi ncr.

•Presence of Indians in international retail market.

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PESTPolitical

•Govt’s “make in India” approach will inc.

manufacturing in India and Indian products.

Social

•Govt’s focus on farmers and rural sector is

expected to boast the economic health of rural India

which will improve consumption of textiles and

apparels.

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PESTEconomical

•Rs 4594.82 crores is allocated to textiles ministry in

2016-17 budget.

•Custom duty reduced to 2.5% from 5% for textile raw

materials.

•2% excise duty will increase cost of ready made

garment by 5-6%.

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PEST

Technological

•Govt aims to double farm income including cotton

producing farms through proper, well planned and

modernized irrigation projects

•Setting up of national skill development inst. For

training purpose

•Construction of fast track roads,NHs and

modernizing ports will enhance the process of doing

business.

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•Low labor productivity

• International competition

• Absenteeism

• Repairs and Rejects

• Training

• Lead Time Delay

Issues

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•What is Lead Time?

Time between the Beginning and completion of a particular

process.

•Importance of “LEAD TIME”

•Time is a great issue in apparel industry as orders are

based on weather, seasons and occasions.

•Demand for different merchandise at shorter period of time is

now the highest preference of Consumer.

• This also leads to getting more order, more profit and

good name in this competitive scenario.

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Research Methodology

OBJECTIVE

RO1

Understanding the work flow of Buying House

RO2

Analysis of lead time delay

RO3

Suggest corrective measure to prevent lead

time delays.

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Objectives Research

Design

Data

Collection

Method

Sampling

Technique

Sample Size Sample

frame

Understandingthe workflow of a buying house.

Exploratory Secondary Internet:

Reports and

Articles

7 ( 2 vendor, 5

mersendiser in

my buying

house.)

Unique

collection

, Sam

apparels,

Kolor

koncepts

To find out the

Reasons of

Lead time

delays

Exploratory

And

Descriptive

Secondary

Primary

Internet:

Reports and

Articles

Informal

Interview

Review

previous

years data

Vendors,

merchandiser,

other staff

UC, kolor

koncepts

buying

house,

sam

apparels.

To give the

suggestion

style wise

Exploratory

And

Descriptive

Secondary

Primary

Internet:

Reports and

Articles

Informal

Interview

Review

previous

years data

Vendors,

Senior

Merchandisers,

Sam

Apparels,

kolor

koncepts

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A. Selection of the topic: The topic of the study was selected by myself and was

approved by my mentor.

While assigning the topic necessary recommendations and suggestions were

provided by the supervisor to make this internship project a well organized and

perfect one.

B.Identifying data sources: Essential data sources, both primary and

secondary, were identified that would be needed to carry out the study and

complete this project.

1. The primary data sources:

A.Face to face conversation with the merchandisers, management

people etc.

B.Practical desk work

C.TNA Calendars for different styles.

D.Relevant file study as provided by the concerned merchandisers

2. Secondary data sources:

A.Visiting various factories.

B. previous case studies.

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WORK FLOW

Proto Sample

Fit Sample

Sales Man Sample

Size Set Sample

Pre Production Sample

Top of Production Sample

Shipment Sample

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Controllable factors Uncontrollable factors

Processing. Changes during bulk

production.

Material shortage Rejections by buyers

Unavailability of trims Fabric quality approved

delays.

Fit related problem Lab dips approval delay.

Incomplete submission Bulk approval delay

Miscommunication Fabrics with higher lead

time

Physical testing failure Chemical testing failure

Artwork delays. Artwork rejections.

FINDINGS

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•Fabric delays.

•Delay from buyers end.

•Miscommunication.

•Rejections.

•Processing delays.

•Artwork reworks.

•Trims unavailability.

•Material procurement delays.

•Fit related problems.

•Changes in specifications.

•Approval delays.

•Testing failures.

•Overbooking by factories.

Factor Affecting Lead Time

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SOME CASES

JS53K005

Issues

▪ Proto sample reject.

▪ Fit-related rejections

Suggestions

Should always ensure the design dossier with

the buyer to avoid any problem in proto

sample.

Should have the proper size set and

measurements to avoid the fitting issues.

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SOME CASES

JS53K001SS

80%cotton,20%nylon net

Issues

▪ Delay from buyer end.

▪ Lab-dips rejected.

Suggestions

Should always keep on reminding the buyer

to give the comments as soon as possible,

So that you can proceed further.

Buyers should also give the local buying

house the right to take small decisions

itself as they have knowledge related all

the styles.

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SOME CASES

JS53K002

80%cotton,20%nylon

Ladder lace 100%cotton

Issues

fabric and trim delays

cutting delays

Suggestions

Factories should always keep fabrics

in- house.

Can increase the cutting layer to

increase the output.

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SOME CASES

JS53K101

100% cotton jersey

Issues

Cutting delays

Suggestions

If cutting is delayed, then we can

increase the cutting layers and we can

even increase the cutting table.

Can add more manpower for cutting

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SOME CASES

JS53K103

100%viscose s/j and

100%cotton voile

Issues

Miscommunication.

Suggestions

Should always take every detail

related to style in mail.

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SOME CASES

JS53K004

100%viscose and

100%cotton voile

Issues

Sewing delays

Processing delays

Suggestions

Can increase the number of machines

for productivity.

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FINDINGS

•Not fully exploiting its resources as a company to reduce the lead time to get a competitive advantage.

•Garment preproduction activities taking 60-70% of total lead-time.

•Pre-production process networks are unique for every single enterprise, every single buyer, even sometimes for every single order and its compulsory to go through same procedure every time which waste lot of time.

•Late delivery of factories.

•Wrong communication lead to more lead time.

•Late delivery of goods to stores/ factories.

•Approvals and submissions were mostly not on time.

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LIMITATIONS

•The research is also expected to plug in the gaps that are existing in

the current procedure.

•After implementing these suggestion we can achieve the target lead

time of 90-100 days as follows.

• Limited time for doing the documentation of the project.

•Limited research work as the project was done on the basis on 1

buying house.

•Limited resources because of fewer vendors and less staff.

•Due to confidentiality, Buying house restrict disclosing some

important data.

•Accuracy of the standard data depends upon the accuracy of the

secondary source as cross checking was not possible.

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