Fab­stract Cloth­ing – A go-to location for value-added gar­ments

Stitch World - - PRODUCTION MANAGEMENT -

Set up in 1991, Fab­stract Cloth­ing has been able to cre­ate a port­fo­lio of pres­ti­gious buy­ers such as Bil­l­abong, Quick­sil­ver (Roxy), O'Neill, and more, over the years. With a turnover of US $ 4 mil­lion, the com­pany has fig­ured out the three main pil­lars be­hind the suc­cess of its busi­ness dur­ing this long ten­ure: Re­la­tion­ship with buy­ers, Cost re­duc­tion and Tech­nol­ogy upgra­da­tion.

Their strong re­la­tion­ship with the buy­ers is the rea­son that they don’t look out for new sup­pli­ers in the mar­ket. “We pre­dom­i­nantly cater to the US buy­ers, with a ma­jor chunk of the pro­duc­tion, that is, 80-85% of pro­duc­tion be­ing ded­i­cated to the USA. The other mar­kets in­cludes France, Swe­den, Italy and Canada,” avers Nitin.

Hav­ing added wo­ven prod­ucts re­cently in its bas­ket, Fab­stract is now a com­plete man­u­fac­tur­ing hub of high fash­ion knit and wo­ven prod­ucts which in­clude ladies tops, dresses and skirts. Right from knit­ting fab­ric, check­ing, cut­ting, stitch­ing to per­form­ing value-added pro­cesses, fin­ish­ing and pack­ing, the man­u­fac­turer han­dles the en­tire ap­parel value chain pro­cesses in-house. In Nitin’s words, “We are not de­pen­dent on out­sourc­ing, there­fore, we try to save over­head cost as much as pos­si­ble through in-house oper­a­tions.”

He also be­lieves that at any point of time, if a man­u­fac­turer tries his hands in any kind of oper­a­tions that need in­vest­ment to up­grade the tech­nol­ogy, he must do that in or­der to sur­vive for a longer pe­riod of time and meet-up the mar­ket ex­pec­ta­tions of timely de­liv­ery while main­tain­ing the ex­pected level of qual­ity in gar­ments.

“Be­ing a high-fash­ion value added prod­uct man­u­fac­turer, we en­cour­age our­selves for in­vest­ment as far as tech­nol­ogy is con­cerned. We keep in­vest­ing money in ad­vanced ma­chin­ery that gives us an edge over other man­u­fac­tur­ers,” claims Nitin.

Stud­ded with com­plete tech­nol­ogy so­lu­tions…

Hav­ing pro­duc­tion ca­pac­ity of 80,000 pieces/month, the unit of Fab­stract is equipped with 250 SNLS Juki ma­chines, 4 Ter­rot cir­cu­lar knit­ting ma­chines, 2 Ta­jima em­broi­dery ma­chines and re­cently bought 3 sta­teof-the-art flat trim Yam­ato ma­chines. Ad­di­tion­ally, for re­source plan­ning in­side the unit, the com­pany has in­stalled Vis­ual GEMS ERP. Whereas, de­sign­ing of prod­ucts is sup­ported by Op­ti­tex CAD soft­ware. “In­creas­ing work­force is never an in­tel­li­gent de­ci­sion when you can have more ben­e­fits with tech­nol­ogy in a longer run,” opines Nitin on the sig­nif­i­cance of au­toma­tion.

Since ma­jor­ity of pro­duc­tion is un­der­taken for knit prod­ucts, Fab­stract knits dou­ble face fabrics on Ter­rot ma­chines. Ex­plain­ing the need of these ma­chines, Nitin says, “In out­sourced knit fabrics, we usu­ally ex­pe­ri­ence prob­lems such as dif­fer­ent GSM and dif­fer­ent counts. Stretch prob­lem too is a ma­jor is­sue that oc­curs in fabrics. Thus, once a buyer con­firms his/ her or­der, we rec­tify the tech­ni­cal flaws while knit­ting fabrics ac­cord­ing to our tested stan­dards,” adding, “This sim­pli­fies our sew­ing op­er­a­tion as the op­er­a­tors get qual­ity fabrics.”

Con­sid­er­ing em­broi­dery as a hot trend for the fu­ture, Nitin shares that he sensed the emerg­ing em­broi­dery mar­ket way back and joined hands with the Ja­panese pi­o­neer Ta­jima to in­stall multi-head em­broi­dery ma­chines. Linked and pro­grammed with com­put­ers, Ta­jima TFGN-620 is the com­pany’s flag­ship model of em­broi­dery ma­chine which is lead­ing Fab­stract rapidly on its way to­wards sup­ply­ing the best of the em­broi­dery prod­ucts. “Our or­der ca­pac­ity is pro­pel­ling us to in­vest in one more em­broi­dery ma­chine by Oc­to­ber this year,” shares Nitin.

Au­tom­a­tiz­ing the fab­ric join­ing process, Fab­stract has re­cently in­tro­duced 3-flat trimmer ma­chine of Yam­ato which is not yet widely con­sumed in the In­dian mar­ket. This 6-thread nee­dle ma­chine is en­abling Fab­stract to join two dif­fer­ent fabrics, i.e. knit and wo­ven, to­gether. “We felt need of these ma­chines as we re­al­ized that Fab­stract is known for its qual­ity and value-ad­di­tion and we can’t com­pro­mise with it. Thus we thought of in­vest­ing in some­thing that is new in the mar­ket and rel­e­vant for us,” com­ments Nitin.

At­tached on the ma­chines is the vac­uum pipe that ab­sorbs all the trimmed fab­ric and elim­i­nates the need of mask for the op­er­a­tor. Most im­por­tantly, these ma­chines have fo­cused light­ing sys­tem in the sew­ing area which im­prove lux level and re­duce vis­ual fa­tigue of the op­er­a­tor,” avers Nitin.

Sus­tain­abil­ity too on the list…

Over­whelmed with its lat­est cer­ti­fi­ca­tion re­ceived from the Global Or­ganic Tex­tile Stan­dard (GOTS), Nitin un­der­lines the fact that the need of or­ganic prod­uct is in­creas­ing in the mar­ket. Cap­tur­ing this need, Fab­stract has re­cently added pure or­ganic cot­ton prod­ucts in its bas­ket to sup­port sus­tain­abil­ity in ap­parel value chain. “Each and ev­ery step of our or­ganic cot­ton prod­uct man­u­fac­tur­ing right from fab­ric dye­ing to ship­ment is ver­i­fied by GOTS,” he con­firmed. Fab­stract is cur­rently loaded with 60,000 pieces of or­ganic cot­ton and is aim­ing to get more or­ders from the US and Euro­pean mar­kets by the end of this year.

“There is no stop­ping for us in near fu­ture and we are plan­ning to es­tab­lish a big­ger state-of-the-art fac­tory in Noida it­self by 2018. We have al­ready bought the land and our team is do­ing tech­ni­cal plan­ning to equip the planned plant with bet­ter ma­chin­ery to ful­fil the larger ca­pac­ity,” con­cludes Nitin.

“Price point at which US fac­to­ries are much higher com­pared to our price points range is be­tween US $ 6 and US $ 12. The mar­ket will stay in ap­parel man­u­fac­tur­ing hubs like In­dia, Bangladesh etc. where the man­u­fac­tur­ing cost does not ex­ceed the set price points,” ex­plains Nitin.

“We do gar­ments that have value ad­di­tion like lo­gos, patches, em­broi­deries etc., which gives us an edge over oth­ers,” shares Nitin proudly.

Nitin Batra, Man­ag­ing Direc­tor, Fab­stract Cloth­ing

Fab­stract re­cently in­vested in Yam­ato flat trim­ming ma­chines

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