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A & A APPAREL MANUFACTURING INDUSTRIES

COMPANY REVIEW

(VISION, MISSION & OBJECTIVES)

The company was initially established in 1969 by Mr. Abid & Mr. adeel in Pakistan. Later on,
as an expansion project, A&A was established in United Arab Emirates nearly two decades ago
to accommodate the growth of orders to the United States of America and European countries.
The company has been running successfully since its inception, currently we have the strength of
more than 3,200 people consisting of, a team of highly professional and efficient management,
workers in our manufacturing unit, and a sourcing office including affiliated factories.

A&A has a state of the art manufacturing setup; it is equipped with most modern and advanced
technologies. This combination with our highly experienced management has enabled the
company to become one of the best apparel manufacturers and suppliers in the region. Strict
quality controls are followed through out the entire process, from the selection of raw materials,
to the production and delivery of the garments. “Complete customer satisfaction” is our prime
objective. "To provide excellent service & quality to our customers all around the world."

Key Production Floor Features

• Equipped with the most modern manufacturing facilities.


• Specialized machinery in order to maintain high standards of quality and efficiency.
• Experience and skilled workers..
• Complete production process under one roof.

At A&A, every garment we sell is of the highest quality, simply because we care, and simply
because it has your name on it. Our products are designed to reflect the pride you have in your
company. Thus we place meticulous attention to every single detail of the garment and assert a
great deal of care in every aspect of the manufacturing process. We want you to "feel good" and
be proud when wearing one of our "A&A" with your company logo embroidered or printed on it.
We value the opportunity to work with you and guarantee to provide; cutting-edge technology,
on time delivery, superb customer service and outstanding quality.

A&A has customers all over the world, a global variety of garments in a variety of fabrics and
colors. You can also customizing your own garments utilizing our unmatched service, and much,
much more.

The Perfect Garment Engineering:-

A&A has never hesitated in adapting the latest manufacturing technologies. The engineering and
sampling department is equipped with latest, Gerber Garment Technology (GGT) Accumark,
designing, grading and marking system. Garments designed at A&A are engineered to
perfection. Being the backbone of the entire manufacturing facility the pattern making and
sampling department at A&A take great pride in creating unmatchable quality garments.
ISO Certification:-

At A&A, garments are produced in our own manufacturing unit, A&A Apparel Mfg. Co., which
is a trend setter and one of the best manufacturing units in the region. A&A is also recognized by
major business organizations around the world. It has achieved various acknowledgments
throughout its journey towards success. The most recent and most significant is the ISO
9001:2000 certification for, the Quality Management System. The realization of our dedication
to professionalism and commitment has become evident as we are the first garment
manufacturing company in the region to achieve this prestigious certification.

Guaranteed Quality:-

Every single garment by A&A is guaranteed for quality and we assure customer satisfaction. The
exceptionally vigilant "Quality Assurance Team" at our manufacturing unit strictly follows our
"No Compromise on Quality" policy. International quality standards are followed to assure that
our customers get full value for their money.

Work Force:-

The company has strength of highly professionals and dedicated workforce manufacturing unit
having experience from 5-25 years in their respective professions. The workforce mainly
comprises of skilled female workers from our county..

At A&A, garments are produced in our own manufacturing unit A&A Apparel Mfg. Co.

Which is the trend setter and one of the best manufacturing units in the region, and this is
acknowledged by major business organizations around the globe. It has achieved various
milestones throughout its journey of success, and the recent and most significant achievement is
the ISO 9001:2000 certification for Quality Management System. This certification has taken our
company on the top, being the first garment manufacturer company in the region to achieve this
prestigious status. This achievement is the symbol of our professionalism and commitment.
A&A is the proven leader in garments sourcing, designing and product innovation. Since its
inception it has been running with one goal, Our outstanding management team and unique
corporate culture have been the driving force behind our success.

Reasons to stay in this business:-

1. The Pakistan textile industry of the country is a major contributor to the national
economy in terms of exports and employment. It holds the credit of being the world's
4th largest producer of cotton, and 3rd largest consumer of the same.
2. The global apparel manufacturing industry is expected to grow more than ever in times to
come. According to an estimate, the global apparel industry will reach a value of US $
1,781.7 billion by the end of 2010.
3. It is a never ending industry, as the customers demand of quality is increasing in textile ,
the scope of apparel manufacturing is increasing.
4. Our strength of cotton is good & has a medium staple length & Pakistan is the 8th largest
exporter of cotton.

Industry Supply Chain:-


The apparel industry supply chain can be broadly categorized into five major components as raw
materials, textile plants, apparel plants, export chains, apparel manufacturers, retail stores and
customers
Major Manufacturers and their Market Share:-
In 2006, the largest apparel manufacturers and exporters were countries from the Asia-Pacific region
which included countries like China, Hong Kong, Philippines, Malaysia, Indonesia, Bangladesh, Srilanka,
Pakistan, Thailand and India. The other major apparel manufacturing nations were USA, Italy, Germany
and Mexico.

Industry Challenges:-
The Apparel Industry is growing at a very high rate but still there are some barriers, which are hindering
the growth of this industry. Some of them are:

• Though the demand for garments is increasing day by day but the production rate has still not
been able to match with the ever rising demand. More production facilities are needed to meet
the demand.

• Most of the raw material needed for apparel manufacturing is available in the developing or under
developed countries and these countries do not have enough resources and manpower to
explore them. These countries also do not have finance to set up factories for clothing and
garment production.

• Globalization has helped the trade in many ways but due to globalization the competition has
increased and so it is not very easy for the firms to cope up with so much competition, as they
have to meet the deadlines and also maintain quality.

• The importers of developed economies are facing very stiff competition as countries like China
are producing good quality products in low prices due to availability of very cheap labour.
• Some trade laws still are very much in favor of developed countries and they need to be
reviewed, to facilitate imports from the developing countries.

• As apparel industry is fashion driven, and fashion keeps changing, the firms have to cope with the
changing apparel industry trends and still complete orders in time. Thus they usually have to work
under pressure.

Future Prospects:-

The global apparel manufacturing industry is expected to grow more than ever in times to come.
According to an estimate, the global apparel industry will reach a value of US $ 1,781.7 billion by the end
of 2010. The apparel manufacturers are now adopting new techniques to increase their
trade. New business models and competitive strategies are used to enhance profits and growth. The
consumer is more aware and more demanding with the development of media like television and Internet.
They have more choices in quality, price and design. This is the reason why apparel chains all over the
world are focusing more on improving the quality of the product and offering in varied range of fashion
designs. Apparel manufacturers are developing methods to keep up with the pace of change like offering
on wholesale prices to survive in the global competition.
HIERARCY OF OUR INDUSTRY
DIRECTOR

GENERAL

MANAGER

MANAGER
HR MANAGER
PRODUCTION
MANAGER
MARKETING MANAGER

TECHNICAL MANAGER
SUPERVISORS
CUTTING SUPERVISOR
STICHING SUPERVISOR
PRESSING SUPERVISOR
FOLDING SUPERVISOR

LABOUR

Different departments of our industry:-

1. Marketing & merchandising.


2. Administration (HR)
3. Planning & complaining.
4. Quality.( QC & QA)
5. Finance.
6. Production. (cutting, stitching, pressing, folding or packing)

Factory Layout:-

Dispatching of apparel Packing & Finishing


goods

Pressing

Washing
(optional)
Stitching of raw material

Arrival of raw material Cutting of raw material


Reasons to be in the business:-

The model of our factory is not vertical, it consist of three unit i.e. modules (unit.1 & unit .2 unit.3). Each
module is designed as above layout diagram is shown the raw materials enters from one side & goes
further line wise to the consequent departments, where as washing is optional & depends on customers
demand. In unit.1 & unit.2 production of normal orders are carried out like polo shirts, where as in unit.3
value edit product orders are carried out. The volume of production of the unit 1 & 2 will be greater but our
main source of concentration will be at unit.3 as % of problem occurrence is more their.

Unit.1 Unit.2 Unit.3

Marketing strategies:-

There are several marketing strategies but the one best for our business that we have adopted is

“Same market different product” because we are not only producing polo shirts & common dress shirts
(uniforms) like other manufacturing firms but also are carrying the production of value edits apparel
products. By taking the value edit product orders we can maintain our level up to maturity, because the
key is product development that we are doing in our industry in unit 3.

Product Line:-
Our basic product is shirt (casual polo shirts, uniforms, dress shirts, value edit shirts)The total area of
each module is 6 acre in which the labour works in 3 shifts each of 8 hours starting from 6.00 A.M in
shifts A,B,C respectively:-

1. 600 stitching machine & workers as well.

2. 20 cutting workers on each table.

3. 92 ironers.
4. Folders & helper’s staff is 76.

Per day production:-

Per piece production in 15 seconds.

1minute = 4 pieces are produced.

4 x 1 hour (6o minutes) = 240 pieces.

240 x 20 working hours (excluding tea & lunch break) = 4800 pieces in one day.

One month production 4800 x 30 = 144000 pieces.

Efficiency per day:

Our total capacity per day = 5300 pieces.

Total production per day = 4800 pieces.

Efficiency per day =5300\4800 x 100 = 90%.


Sales Forecast:-

Production capacity is calculated by our last annual most production & for value edit products we have
reduces our production capacity & increased per piece price a bit, but the price is set minimum as
possible by identifying product according to the market & our industry expertise. Our per year capacity is
1908000 pieces but our annual production is 1728000 pieces, so per piece cost = 200Rs & it is sold at
400Rs so the per profit is 200Rs so the total net profit per year is = 33828000Rs (by subtracting all
salaries & utility bills).

For focusing our production increment from 1728000 to 1800000 pieces next year. We will increase our
production through.

1. Past experiences.
2. Marketing strategies.
3. Increasing machinery.
4. Hiring contract based labour.

Material and sourcing:-

In sourcing most cost effective vendors or production facility at specific quality & service level.

1. Sourcing material (piece goods & findings).

Piece goods: - piece goods are the pieces of the raw material (fabric) making the product.

Findings: - Findings contain trims & accessories

Trims: - essentials like button, zips, thread.

Accessories: - Tags & labels.

We have to determine 3 facts

1. Quality.
2. Price.
3. Service.

We are sourcing our material from ASA (apparel sourcing America), which operates imports and
exports of all kinds of apparel products, accessories and home furnishing products, Apparel
Sourcing America is a global sourcing company cooperating with more than 300 contract
manufacturers. Different from an common trade company, it provide comprehensive services for both
buyers and suppliers giving a great deal of delivery time, Payment terms & after sales. Since we are
the manufacturer of the shirts we out source findings i.e. tag, labels, threads & buttons. We outsource
fabric as well as some important findings according to the requirement as mentioned above, so we
don’t use “existing order” where the fabric is kept in stock i.e. the fabric construction remains same
but product can change or can be fulfilled by another design, hence we follow the “make to order”
policy stocking is not done otherwise the firm can face losses as the rapid change of market trend
only the given order is fulfilled.

Garment Analysis:-

1. PRODUCT POSITIONING STRATEGY


The foundation for garment analysis is the purpose or intended use of garment. Factors that is useful in
describing a product’s purpose and styling include functional / aesthetic priorities, durable / disposable
performance, intrinsic / extrinsic cues to quality, basic / fashion styles, non-seasonal / seasonal use, and
low end / budget / moderate / better / designer price ranges.

A) Functional or esthetic.

B) Intrinsic or extrinsic.

C) Basic Styling/ Fashion Styling.

D) Non seasonal/ Seasonal.

E) Budget price/ Moderate/ Better price.

A B C D E A B C D E

5 4 3 2 1 1 2 3 4 5

5 4 3 2 1 1 2 3 4 5

5 4 3 2 1 1 2 3 4 5

5 4 3 2 1 1 2 3 4 5

5 4 3 2 1 1 2 3 4 5

Functional Aesthetics
2. SIZING AND FIT

We & the, consumers are concerned about sizing and fit. Consumers seek garments that provide an
attractive appearance and comfort during wear. The challenge is to offer consistency in sizing among
styles, product lines and seasonal offerings. Customers want to be able to select the same size for a new
style of a favorite brand name and have it fit in a similar manner to products already owned. The size & fit
varies form place to place & region to region. So the standard for each region are followed for e.g.

Chest S M L XL XXL

42 45 48 51 54

Body length 30 30.5 31 31.5 32

3. MATERIAL SELECTION

Materials used in apparel manufacturing include fabrics, support shaping materials, trims, closures,
threads, labels and accessories. Proper selection and consistent quality of materials are important to
apparel quality and performance. One incorrect or inferior material can impart a lower quality level to the
entire garment. The quality of materials must also be consistent with the product positioning strategy. The
technical nature of quality and performance of materials, such as strength, abrasion resistance, resiliency,
pilling and snagging resistance, and colorfastness are also important factors for garments in which
intrinsic quality and durability are particular concerns. The criteria for analysis of material include material
name, material content, yarn type/size, fabrication, count/gauge, weight/size, hand/drape ability,
structural/applied design, color, finishes, care and method of application.

4. COMPONENT ASSEMBLY

A garment component is a garment part that requires one or more separate pieces to be assembled as a
unit. Garment components are the basic sections of garments including top fronts, top backs, bottom
fronts, bottom backs, sleeves, collars / neckline treatments, cuffs / sleeve treatments, plackets, pockets,
and waistline treatments. The criteria for analysis of garment components include identifying components,
determining the number of pieces and number of materials in each component, the operational
breakdown, types of stitches and seams, compatibility among materials, compatibility of materials and
assembly methods, degree of enclosure, and pressing etc.

5. FINAL ASSEMBLY AND FINISHING

It is the process to combine garment components and produce the finished appearance of the garment.
Processes that might be included in final assembly include attaching collars, setting sleeves, attaching
waist bands, inserting linings, closing side seams and forming hems. Small components are attached to
larger components such as pockets to fronts, plackets to sleeves, and waist bands to skirts or pants.
Combined components are assembled to make a complete garment by inserting linings and / or closing
seams. Minimizing handling is a primary factor that may determine the sequence of final assembly.
Potential steps in garment finishing include trimming, wet-processing, garment dyeing, and final pressing.

6. GARMENT PRESENTATION

It includes hanger or shelf appeal, labeling and ticketing, accessories and packaging.

Management of Quality:-

Quality has to be taken care by the exporter, excuses are not entertained in international market for
negligence for low quality garments, new or existing exporters for both it is mandatory to use design,
technology and quality as major up gradation tools.

. Apart from superior quality of the garment, its pricing, packaging, delivery, etc has to be also taken care
of.

. The garment shown in the catalogue should match with the final garment delivered.

. It is important to perform according to the promises given to the buyer, or else it creates very bad
impression and results in loss of business and reputation.

. In international market, quality reassurance is required at every point.

. Proper documentation and high standard labels on the garment are also important aspects as these
things also create good impression.

. Timely delivery of garments is as important as its quality.

. If your competitor has the better quality of garment in same pricing, it is better to also enhance your
garment quality.

. Before entering into international market, garment exporters have to carefully frame out the quality
standards, or else if anything goes wrong it could harm the organization. And after that strictly follow it.

. The garment quality should match the samples shown during taking the orders.

. The garment exporters should know to negotiate a premium price after quality assurance is done.

Quality is a multi-dimensional aspect. There are many aspects of quality based on which the garment
exporters are supposed to work.

. Quality of the production.

. Quality of the design of the garment.

. Purchasing functions' quality should also be maintained.

. Quality of final inspection should be superior.

. Quality of the sales has to be also maintained.

. Quality of marketing of the final product is also important as the quality of the garment itself.
There are certain quality related problems in garment manufacturing that should not be overlooked:

Sewing defects - Like open seams, wrong stitching techniques used, same colour garment, but usage of
different colour threads on the garment, miss out of stitches in between, creasing of the garment,
erroneous thread tension and raw edges are some sewing defects that could occur so should be taken
care of.

Colour effects - Colour defects that could occur are - difference of the colour of final produced garment to
the sample shown, accessories used are of wrong colour combination and mismatching of dye amongst
the pieces.

Sizing defects - Wrong gradation of sizes, difference in measurement of a garment part from other, for
example- sleeves of 'XL' size but body of 'L' size. Such defects do not occur has to be seen too.

Garment defects - During manufacturing process defects could occur like - faulty zippers, irregular
hemming, loose buttons, raw edges, improper button holes, uneven parts, inappropriate trimming, and
difference in fabric colours.

Conclusion:-

Quality is ultimately a question of customer satisfaction. Good Quality increases the value of a product or
service, establishes brand name, and builds up good reputation for the garment exporter, which in turn
results into consumer satisfaction, high sales and foreign exchange for the country. The perceived quality
of a garment is the result of a number of aspects, which together help achieve the desired level of
satisfaction for the customer. Therefore quality control in terms of garment, pre-sales service, posts -sales
service, delivery, pricing, etc are essentials for any garment exporter.