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