Pa­cific Gar­ments: 42 years of le­gacy in niche

Stitch World - - PRODUCTION MANAGEMENT -

Em­brac­ing pas­sion for their prod­ucts, Pa­cific Gar­ments man­u­fac­tures wo­ven women’s dresses, tops, blouses, shirts, ca­sual pants and stoles which are a per­fect blend of in­no­va­tion, fash­ion and style. “The fash­ion in Ja­pan is ex­tremely dif­fer­ent from any­where in the world. Men, on one hand, are more in­clined to­wards busi­ness suit­ings whereas, women’s fash­ion state­ment con­sists of at least five lay­ers of cloth­ing, start­ing from lin­gerie, camisole to shirt, blazer com­ple­mented with a stole,” said Rakesh Gupta, the young face of the com­pany steer­ing the busi­ness.

De­fined by small quan­tity, ex­clu­sive and ex­pen­sive, niche de­mands a ded­i­cated team and an or­ga­nized set-up from de­sign to man­u­fac­tur­ing. With a wide range of sew­ing ma­chines, Pa­cific Gar­ments takes up or­ders as low as 30 pieces that can go up to 30005000 pieces. As in a mass ap­parel man­u­fac­tur­ing fa­cil­ity, the com­pany fol­lows as­sem­bly line sys­tem to man­u­fac­ture higher or­der quan­ti­ties. In case of small or­der quan­ti­ties, the same as­sem­bly line is treated as a num­ber of as­sem­bly lines.

“For in­stance, an as­sem­bly line con­sists of 28 op­er­a­tors. A style to be man­u­fac­tured has the or­der quan­tity of 500-1000 pieces. The same as­sem­bly line would be bro­ken in to groups of 3-4 if the or­der quan­tity is around 50-100 pieces or even less,” ex­plains Rakesh. How­ever, he avers that not only the mass man­u­fac­tur­ers but also the niche man­u­fac­tur­ers like him are fac­ing the wave of strong com­pe­ti­tion. “Prices are falling, profit mar­gins are de­creas­ing. There are some man­u­fac­tur­ers in the mar­ket that give the prod­ucts at throw­away prices,” shares Rakesh, fur­ther adding to his woes, “These man­u­fac­tur­ers are pos­ing a big threat to the or­ga­nized busi­ness be­cause they in­tend to do one-time busi­ness and then move out of the busi­ness, leav­ing oth­ers to suf­fer with the in­creased com­pe­ti­tion.”

‘Green’ Pa­cific Gar­ments is con­structed from fly ash bricks rather than banned ba­sic bricks which help the build­ing to re­main 30% more cool.

Of­fer­ing a new prod­uct with value ad­di­tion and new de­sign ele­ments are the se­crets that have kept Pa­cific Gar­ments in busi­ness all these years and helped it pros­per. “Our prod­ucts are less au­to­mated and more man­ual. New prod­ucts and new de­signs are our se­cret to sur­vival,” avers Rakesh. Though there is fab­ric wastage and low ef­fi­ciency, the new de­signs and a shift from ba­sic are the sus­tain­ing fac­tors for this niche busi­ness.

Mean­while, am­ple use of work­force does not mean that Pa­cific is not in­clined to­wards ‘Ma­chine Tech­nol­ogy’. Since hu­man ef­forts are just not enough to han­dle the sys­tem ef­fi­ciently, Pa­cific has adopted tech­no­log­i­cal so­lu­tions. To avoid delays, un­planned cir­cum­stances and mon­i­tor pro­duc­tion, it is equipped with Texma ERP. This in­di­cates that the need of tech­nol­ogy in the com­pany does not go awry. “Use of hu­mans more than the use of tech­nol­ogy never means that tech­nol­ogy is not a need for us. Rather it’s just we have a cul­ture to pro­mote ar­ti­sans by pro­vid­ing them sta­ble em­ploy­ment,” says San­deep Do­briyal, Direc­tor, Pa­cific Gar­ments.

Apart from these ex­cel­len­cies, Pa­cific Gar­ments also fol­lows var­i­ous man­age­ment sys­tems in its fa­cil­ity to in­te­grate qual­ity and ex­cel­lence not only in their prod­ucts but in each and ev­ery depart­ment of the fa­cil­ity. The com­pany fol­lows a penalty sys­tem where peo­ple com­mit­ting mis­takes or break­ing rules, have to pay a cer­tain amount of fine ir­re­spec­tive of whether they are from the top man­age­ment such as MD or Chair­man, sew­ing op­er­a­tors or fin­ish­ing op­er­a­tors. “How­ever, the amount of fine is higher for the top man­age­ment and some­what less for the mid man­age­ment,” says Rakesh with a tone of hu­mour.

The com­pany takes care of both com­pli­ance and sus­tain­abil­ity as the core re­quire­ments of the fa­cil­ity. It is equipped with the ETP plant and a rain­wa­ter har­vest­ing plant in its premises.

The amount of money col­lected at the end of the month from the fine is then handed over to dif­fer­ent de­part­ments, one at a time. “The re­spec­tive depart­ment can have snacks and tea party from that money. This kind of prac­tice has helped me in­tro­duce a sense of re­spon­si­bil­ity among my staff and a stronger bond­ing,” shares Rakesh.

Fur­ther­more, to keep op­er­a­tors trans­par­ent and aware about the work-flow, there are clear in­struc­tions given to the su­per­vi­sors to con­duct manda­tory morn­ing meet­ings on daily ba­sis just be­fore the start­ing of pro­duc­tion. “We have made a sys­tem where we en­sure not to skip any of the meet­ings no mat­ter what comes up as ur­gent, which makes our op­er­a­tors know the value of dead­lines and qual­ity,” says Rakesh.

Sim­i­larly for his com­pany, pieces of frag­mented nee­dle in a gar­ment is a big no… Nee­dle check in all gar­ment is a must be­fore send­ing them to pack­ing de­part­ments. The buy­ers man­date the pass­ing of the gar­ment piece through nee­dle de­tec­tor ma­chine. For Ja­panese buy­ers, the vi­o­la­tion of this re­quire­ment makes sup­pli­ers pay a very hefty for­feit. “There is a penalty of US $ 2000 per piece in Ja­pan for such neg­li­gence,” high­lights Rakesh.

Pa­cific Gar­ments fol­lows com­pli­ance very strictly in its fa­cil­ity. Fur­ther­more, to leave no loose ends, the com­pany is main­tain­ing the prac­tice of pack­ing depart­ment as a ‘metal free zone’. It pe­nal­izes a per­son with a fine of Rs. 500 if he/ she is found walk­ing in the depart­ment with a gar­ment in his/her hand. It pro­motes pass­ing of the gar­ment through the nee­dle de­tec­tor first and then walk­ing in­side bare handed.

“We have been fol­low­ing this prac­tice in our fac­tory from last 5 years,” Rakesh states proudly. Be­sides, Pa­cific Gar­ments has in­tro­duced leather slip­pers for the staff and the op­er­a­tors in their fa­cil­ity that ought to be worn while en­ter­ing the pack­ing depart­ment. The per­son has to take off the footwear he/she is wear­ing and wear leather slip­pers be­fore en­ter­ing the pack­ing depart­ment to avoid the en­trance of any for­eign ma­te­rial. “This will help us main­tain clean­li­ness in the pack­ing depart­ment. Also, I am plan­ning to adopt this prac­tice in other de­part­ments as well,” in­forms Rakesh.

Mad­hushree Gupta (C), Direc­tor with Rakesh Gupta (L), Direc­tor (Mar­ket­ing) and San­deep Do­briyal, Direc­tor, Pa­cific Gar­ments

The com­pany uses leather slip­pers while en­ter­ing the pack­ing depart­ment to avoid en­trance of for­eign ma­te­ri­als

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