PEARL ACADEMY 1

DEPARTMENT OF FASHION
MERCHANDISING

“LEAD TIME COMPRESSION”

Submitted by:
Mohd Ubaid
(2014 - 2016)
 INTRODUCTION TO
“Kolor Koncepts”

 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

2
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

APPARELS

MENS WOMENS KIDS 3

BUYERS

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 VENDOR

• Unique collection
• Sam apparels
• Certitude
• vishesh apparels
• shorshots
• kalamakri
•Textline Apparel
• Maya Exports

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 Organization structure

DIRECTOR

PRODUCTION PRODUCTION ACCOUNTS

MANAGER MANAGER

BOOKING
MERCHANDISER MERCHANDISER
DEPT.

QUALITY QUALITY
CONTROL CONTROL

SAMPLING

FINISHING

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 SWOT
S-Strength

•Emphasizes and values its consumers the most.

•It lays stress on long term relations and therefore has a

very strong customer loyalty.

•They try and adopt a process which is full of research,

innovation, tested and tried that best serves the
customers..
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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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 PEST
Political

•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
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apparels.
 PEST
Economical

•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
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business.
 Issues
•Low labor productivity
• International competition
• Absenteeism
• Repairs and Rejects
• Training
• Lead Time Delay

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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

RO1
Understanding the work
flow of Buying House

RO2
OBJECTIVE Analysis of lead time
delay

RO3
Suggest corrective
measure to prevent lead
time delays.
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Objectives Research Data Sampling Sample Size Sample
Design Collection Technique frame
Method

Understanding Exploratory Secondary Internet: 7 ( 2 vendor, 5 Unique

the workflow of Reports and mersendiser in collection
Articles my buying , Sam
a buying house. house.)
apparels,
Kolor
koncepts
To find out the Exploratory Secondary Internet: Vendors, UC, kolor
Reasons of And Primary Reports and merchandiser, koncepts
Descriptive Articles other staff buying
Lead time
delays Informal house,
Interview sam
Review apparels.
previous
years data
To give the Exploratory Secondary Internet: Vendors, Sam
suggestion And Primary Reports and Senior Apparels,
Descriptive Articles Merchandisers, kolor
style wise
Informal koncepts
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Interview
Review
previous
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. 18
 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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 FINDINGS
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

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 Artwork delays.  Artwork rejections.
 Factor Affecting Lead Time

•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. 21
 SOME CASES

Issues
▪ Proto sample reject.
▪ Fit-related rejections

Suggestions
 Should always ensure the design dossier with
the buyer to avoid any problem in proto
sample.
JS53K005  Should have the proper size set and
measurements to avoid the fitting issues.

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 SOME CASES

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.
JS53K001SS  Buyers should also give the local buying
80%cotton,20%nylon net
house the right to take small decisions
itself as they have knowledge related all
the styles.
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 SOME CASES

Issues

 fabric and trim delays

 cutting delays
Suggestions

Factories should always keep fabrics

JS53K002 in- house.
80%cotton,20%nylon
Ladder lace 100%cotton Can increase the cutting layer to
increase the output.

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 SOME CASES

Issues

 Cutting delays

Suggestions

If cutting is delayed, then we can

increase the cutting layers and we can
JS53K101 even increase the cutting table.
100% cotton jersey
Can add more manpower for cutting

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 SOME CASES

Issues

 Miscommunication.

Suggestions

Should always take every detail

related to style in mail.
JS53K103
100%viscose s/j and
100%cotton voile

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 SOME CASES

Issues

Sewing delays
Processing delays

Suggestions

Can increase the number of machines

JS53K004
for productivity.

100%viscose and
100%cotton voile

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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.

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•Approvals and submissions were mostly not on time.
 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 29

secondary source as cross checking was not possible.

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