Con­cept Cloth­ing – Win­ning ‘Tug of War’ with ‘Tech­nol­ogy and Qual­ity’ com­bi­na­tion

Stitch World - - PRODUCTION MANAGEMENT -

Con­cept Cloth­ing has be­come a US $ 20 mil­lion group with 5 pro­duc­tion units in Gur­gaon with con­tin­u­ous ex­pan­sions and vi­sion­ary ap­proach. The man­u­fac­turer is al­ready work­ing with cloth­ing gi­ants such as Zara (Spain), Free Peo­ple (USA) and Next (UK).

It pro­vides the best qual­ity prod­ucts and uses lat­est pro­duc­tion tech­nolo­gies and the skills of a highly in­no­va­tive de­sign team to en­tice buy­ers. Con­cept Cloth­ing has ev­ery­thing in place, strate­gi­cally. The com­pany has a well-built de­sign team which is en­gaged in con­tin­u­ous prod­uct de­vel­op­ment ex­er­cise. “Apart from buy­ers’ nom­i­nated de­signs, we of­fer them our de­signs too which we cre­ate us­ing our ex­ten­sive and in-depth mar­ket re­search. This, at times, helps us in cre­at­ing ad­di­tional busi­ness from the buy­ers,” com­ments Sanjay Mehta, Di­rec­tor, Con­cept Cloth­ing.

Qual­ity is main­tained in a way it is de­fined by the QMS (Qual­ity Man­age­ment Sys­tem). We just don’t do it for the sake of do­ing it as we know the mean­ing of qual­ity for our buy­ers. Pro­duc­ing high­qual­ity gar­ments is our habit and our buy­ers can rely on this habit.

To avoid bot­tle­necks dur­ing the pro­duc­tion process, Con­cept’s de­sign team pre­pares risk as­sess­ment at

Sanjay Mehta, Di­rec­tor, Con­cept Cloth­ing

the time of de­sign phase with the help of pro­duc­tion and qual­ity teams. “We iden­tify pos­si­ble fac­tors such as short­age of raw ma­te­ri­als, prob­a­ble com­mu­ni­ca­tion gaps, qual­ity er­rors and de­fects in gar­ments that may in­ter­rupt the sup­ply chain and pro­duc­tion. Do­ing this, we op­ti­mize and stream­line our pro­cesses to ob­tain smooth level of pro­duc­tion,” elab­o­rates Sanjay.

Once risk as­sess­ment is done, pro­duc­tion is taken care of through the in­stalled lat­est state-of-the-art ma­chin­ery. In an era where most of the gar­ment man­u­fac­tur­ers are hes­i­tat­ing to in­vest in tech­no­log­i­cal so­lu­tions even for pro­duc­tion, Con­cept Cloth­ing is us­ing au­to­matic thread trim­ming machine in its fin­ish­ing area. It is equipped with 1,500 UBT and dig­i­tal feed SNLS ma­chines from AOTORI brand. For val­uead­di­tion in gar­ments through em­broi­dery, the com­pany has in­vested in Baru­dan 18-head em­broi­dery machine. Cut­ting is ac­quired through East­man cut­ters; marker mak­ing and pat­tern grad­ing is done through Tukat­ech and As­tor soft­ware.

“We have to con­fess that tech­nol­ogy al­ways helps in re­duc­ing the cost of pro­duc­tion, there­fore, re­frain­ing from this will im­pact man­u­fac­tur­ers neg­a­tively in the longer run since the present time is all about a ‘tug of war’ be­tween the buyer and the man­u­fac­turer as far as mar­gins in man­u­fac­tur­ing are con­cerned. Even our soft­ware so­lu­tions have helped us re­duce fab­ric wastage by 5%,” ex­plains Sanjay.

Ac­cord­ing to Sanjay, pro­duc­tion can never be ob­tained ac­cord­ing to the set tar­gets if there is no sys­tem­atic ar­range­ment on the shopfloor in terms of ma­te­rial man­age­ment. To avoid the time con­sump­tion in fre­quent ma­te­rial trans­porta­tion from one end to an­other, Con­cept Cloth­ing fol­lows lean en­gi­neer­ing ex­ten­sively across the unit. The com­pany uses lean pro­cesses to im­prove the shopfloor

The com­pany is tar­get­ing an­other 10-12% in­cre­ment in its turnover dur­ing FY 2017-18.

ef­fi­ciency with no or less money in­volved. In the en­tire fac­tory, no un­de­fined ma­te­rial can be found ly­ing ran­domly on the floor. “Our gang­ways are clearly vis­i­ble and ma­te­rial free as we have given clear in­struc­tions to our em­ploy­ees to use it only for the move­ment of ma­te­rial and not to stack fab­ric or other ma­te­ri­als,” says Sanjay.

The com­pany is dif­fer­ent from other ex­port houses as far as pro­duc­tion prac­tices are con­cerned. It im­ple­ments a ‘pro­duc­tion-fin­ish­ing-wash­ing/pack­ag­ing on the same floor’ sys­tem. Club­bing all three pro­cesses to be car­ried out on the same floor as­sists the com­pany in sav­ing the gar­ment move­ment time con­sump­tion from one area to an­other. This prac­tice, no doubt, in­creases the ef­fi­ciency of the shopfloor with re­duc­tion in cost of over­all op­er­a­tion.

“Our over­all floor ef­fi­ciency achieved is nearly 72%. We are geared up to reach 80% by the end of this year,” claims Sanjay.

Con­cept Cloth­ing is equipped with 1,500 UBT and dig­i­tal feed SNLS ma­chines from AOTORI brand. It also has Baru­dan 18- head em­broi­dery machine.

The en­tire pro­duc­tion floor is equipped with LED lights which help them in power sav­ing as well as less heat scat­ter­ing across pro­duc­tion area.

Con­cept Cloth­ing’s pro­duc­tion floor com­bines both sewing and fin­ish­ing op­er­a­tions

East­man’s band knife cut­ter EC-900N at Con­cepts’ cut­ting floor

Con­cept Cloth­ing in­te­grates sewing, fin­ish­ing and wash­ing on the same floor

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