Amin Idrees

1
1000 Rupees 3 Pc Suit
Jacquard woven

By

Rang O Hunar
2
EXECUTIVE SUMMARY:
Rang-o-Hunar was established on 10th November 2013 with just 10 looms
to manufacture not just clothing, but a true canvas for a designer to express
the creativity using jacquard technique. Durable in affordable able price for
the ladies with sense of style and modernity with a classic sense touch,
We are aiming to be one of the top companies in the field of textile in
Pakistan. The company will be involved in manufacturing and retailing of
greigh, finish custom jacquard woven suiting fabric for men and women.

BACKGROUND:
The company was established in 2013 from a small unit within an area of just
800 SQUARE FT in Karachi the business hub.

WHAT WE DO:
Our business aim is to bring out some exquisite and most extraordinary
eastern wears for our customers. We want to deliver the high quality and
distinctive garments to our customers to fulfill their needs. The Jacquard
woven suit manufacturing and sales systems market, especially in Pakistan
has been characterized by the rapid growth and intense competition. In order
to progress ahead RANG-O-HUNAR will develop deep customer relationships
that nurture loyalty.

PRODUCT INTRODUCTION:
Our product is ultimate fusion of creativity, durability and affordability. It’
s
basically 3 piece suiting, woven on jacquard looms for women, catering the
teens, working women , house wives and gracefully aging ladies.

Jacquard weaving is done on a specialized loom called a Jacquard loom. The

Jacquard loom is a mechanical loom that was invented by Joseph Marie
3
Jacquard in 1801. The jacquard loom simplifies the process of weaving
complicated textile patterns with CAD CAM System creating eye catching
designs and quality of our product “3 piece suiting ladies”make them a
product par excellence. The thorough inspection and immaculate visualization
leads to a matchless collection of products, craft with the most durable fabric
by skilled craftsmen who hail from premier professional institutes and
industries.

ORGANIZATIONALHIERARCHY

4
SALARYSTRUCTURE

5
SALARY DISTRIBUTION:

6
ADMINISTRATION NO. OF SALARY TOTAL
EMPLOY
ES
DIRECTOR 1 100000 100,0 00
GENERAL MANAGER 1 75,00 0 75,00 0
FINANCE MANAGER 1 40,00 0 40,00 0
ASSISTANT (FINANCE) 1 15,00 0 15,00 0
PLANNING/ INVENTORYMANAGER 1 30,00 0 30,00 0
MARKETER/ MERCHANDISER 1 25,00 0 25,00 0
SECURITYGUARD 4 10000 40,00 0
TEACUM SWEEPER 2 8000 16,00 0
DRIVER 1 10000 10,00 0
TOTAL EMPLOYEES 13 351,000

PRODUCTION NO. OF SALARY TOTAL

EMPLOYEE
S
MASTER 1 40,00 0 40,000
WARPER 2 10000 20,000
WEAVERS 10 10000 100 ,000
FOREMANS 4 12000 48,000
DESIGNERS 2 15000 30,000
Q.C 1 12000 12,000
INCHARGE PACKAGING 1 15000 15,000
ASSISTANT PACKAGING 2 8000 16,000
TOTAL EMPLOYEES 23 281,000

MARKETINGPLAN:
As our product is a jacquard woven suite for girls and women with having
some textures and bright colors. The initial phase of the marketing is
marketing plan development.
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Its USP is AFFORDABILITY ,HIGH QUALITY, DURABILITY jacquard woven
suites.

MARKETINGMIX:
For the marketing of our product we follow marketing mix approaches.

1. Pricing: will be based on achieving a specific margin for each suite.

2. Distribution: we ship all products to nationally over different cities.
3. Adve rtising and Promotion: We will use BTL activity for promoting
the product. Social media Facebook will be the main tool.

Our major competitors are khadi, gullahmed. These are large brands and also
exist in the market but they are catering high class market and upper middle
class market.
It is the opportunity for us to cater middle class customers as well.Although it
is a sophisticated product which represents the class and delicacy and
everyone cannot think to buy it.
So we have kept minimum profits at the introductory stage to build good
customer relationship.
The pricing of a suit will be 1000 which is easily affordable for middle class
upper middle class and for niche class.

MARKETINGOBJECTIVES:
Ø To build up a customer database by 25% each year.
Ø To increase the efficiency of the marketing campaigning by 3% each
quarter.
Ø To generate a 15% increase in click through traffic for the website.

TARGET MARKET:
Ø Young girls and women of middle class.

SWOT ANALYSIS

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 STRENGTH :

" STRONGBRAND NAME

" HIGH QUALITY
" NEW STOCK EVERYMONTH
" AFFORDABILITY
" MASS PRODUCTION

WEAKNESS:
" SALES PERSONNEL
" WEAK MARKETINGFUNCTION
" WEBSITE

OPPORTUNITY:
" MARKET DEVELOPMENT
" PRODUCT DEVELOPMENT

THREATS:
" STONGCOMPETITORS E.g; J.J , KHADI ,GULL AHMED,ALKARAM,KHADI
" RECESSION
" DESIGNS REPLICAS

9
FINANCE:
SALARIES:
POSITION SALARY NO OF TOTAL REMARK ADMIN MANUFA
S
PER EMPLOY SALARY
HEAD EE
DIRECTOR 1 100,000 100 %
100,000 adm in 100,000 -
GENERAL MANAGER 1 75,000 100 %
75,000 adm in 75,000 -
FINANCE MANAGER 1 40,000 100 %
40,000 adm in 40,000 -
ASSISTANT (FINANCE) 1 15,000 100 %
15,000 adm in 15,000 -
PLANNING/ INVENTORY 1 30,000 100 %
MANAGER 30,000 adm in 30,000 -
MARKETER/ MERCHAN 1 25,000 100 %
DISER 25,000 adm in 25,000 -
SECURITYGUARD 4 40,000 100 %
10,000 adm in 40,000 -
TEA CUM SWEEPER 2 16,000 100 %
8,000 adm in 16,000 -
DRIVER 1 10,000 100 %
10,000 adm in 10,000 -
MASTER 1 40,000 100% -
40,000 Manufac 40,000
WARPER 2 20,000 100% -
10,000 Manufac 20,000
WEAVERS 10 100,000 100% -
10,000 Manufac 100,000
FOREMANS 4 48,000 100% -
12,000 Manufac 48,000
DESIGNERS 2 30,000 100% -
15,000 Manufac 30,000
Q.C 1 12,000 100% - Total
12,000 Manufac 12,000
INCHARGE 1 15,000 100% -
FOLDING/ PACKAGING 15,000 Manufac 15,000
ASSISTANT 2 16,000 100% -
FOLDING/ PACKAGING 8,000 Manufac 16,000
36 632,000 632,000
351,000 281,000

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BILLS
QUANTI TOTAL Re marks ADMIN MANUFA
TY
GAS - 10%admin 3,000
30,000 27,000
ELECTRICITY - 10% a dmin 9,000
90,000 81,000
COMMUNICATION - 90%admin 7,200
8,000 800
RENT LAND @ 50 800 Sq Ft 30%admin
40,000 12,00 0 28,000
RENT MACHINERY @ 10 100% -
2 0000 LOOMS 200,000 Manufac 200 ,000
TRANSPORTATION 2 100%
VEHICAL 12,000 admin 12,00 0 -
STATIONARY - 90%admin 4,500
5,000 500
KITCHEN - 50%admin 2,500
5,000 2,500
OTHERS - 50% a dmin 2,500 Total
5,000 2,500
PARTS - 100% -
100,000 Manufac 100 ,000
PACKAGINGS - 100% -
10,000 Manufac 10,000

505 ,0 00 52 ,7 00 .0 0 4 52 ,3 00 505 ,0 00

RAW
MATERIALS
Items unit cost unit produce Cost
yar n pe r 3 pc suit 602 9600 5779200
pa cka gings - - 10000
oil gr ease - - 20000 To tal
other s - - 5000
5 81 420 0

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TRANSPORTATION
COS QUANTIT REMARKS TOTAL
T Y
CARTRIDGE YARN @ 2000 1500 250 BAGS 1 TRIP = 85 4687.5
BAGS
CARTRIDGE FABRIC (FOLDING TO 1200 76800 1 TRIP= 18000 5120
SHEARING) MTRS
CARTRIDGE FABRIC ( SHEARING TO 1200 76800 1 TRIP= 18000 5120 TOTAL
DYEING) MTRS
CARTRIDGE FABRIC ( DYEING TO 1200 76800 1 TRIP= 18000 5120
FOLDING) MTRS
CARTRIDGE OTHERS 2000 220 47 .5

PROCESSES
QUANTITY REMARKS TOTAL

DYEING @ 17 PER 76800 OUT SOURCE 1 305600 TOTAL

METER MTRS
SHEARING @ 1 PER 76800 OUTSOURCE 7 6800
METER MTRS
1 38 24 00

PER MONTH COST SUMMARY

Total MANUFA Admin
SALARIES 632,000 28100 0 35100 0
RAW MAETRIAL 5,814,2 00 58142 00 0
BILLS 505,000 45230 0 52700
PROCESSES 1,382,4 00 13824 00 0
TRANSPORTATIONS 22,04 8 22047 .5 0

TOTAL 8,3 55 ,6 48 7 951 94 7.5 4 037 00

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PRODUCTIONOF COMPLETE SUIT (units)
24 HOURS 3 0 DAYS
1 loom 32.00 960.00
1 0 loom 320.00 9600.00 76800 METRS

COST PER 3 PIECE SUIT 870.3 8

COST PER METER 108.8 0

Income state ment:

Per Month
units amount
Ma nufactur er Cost per 1 870
Ma nufactur er selling pr ice pe r 1 1000
Tota l sales 9600 96000 00
COG 9600 79519 47
Gr oss pr ofit 16480 53

Admin expenses 40370 0

Net Profit 12443 53

Ma nufactur er Mar gin 21%

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COMPANYDETAILS:

The company was established in 2013 from a small unit with an area of just
800 SQUARE FT having three floors. Ground floor has Administration, offices
and Weaving looms production depth and folding, First floor has yarn
warehouse and Warping area while the second floor has fabric warehouse.
We have a capacity of 20 looms but initially we will start with only 10 looms.

The company has invested in the latest technology to produce cost effective
and high quality jacquard fabric in accordance with the customer’ s need . The
company’ s state of the art production facility located in the main industrial
area spread over 800 SQ FEET .

The company’
s production facility has fully integrated production lines by
starting

Design Dept(CAD CAM)

Warping

Weaving

Quality checking and Inspection

Folding / Packiging

WEAVINGDEPARTMENT SUMMARY:

No of weaving looms 10
Width 110"
loom manufacturer sulzer
loom type P7100

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 Jacquard manufacturer JC4
RPM 250
No of Insertion 4 wefts

PRODUCT DETAILS:

Jacquard wove n 3 piece s uit for ladies :

Our product cons ists of 3 ite ms :

Item Length Quality(cons truction )

1 Dupatta 2.5m 40/ 2 x 40/ 2 x 150 x 150 x 48 x 46(67.60) = 49”
2 Kameez 3m 40/ 2 x 40/ 2 x 150 x 150 x 48 x 46(76.91) = 49”
3 Shalwar 2.5m 40/ 2 x 40/ 2 x 48 x 46 = 49”

COLORS AND DESIGN:

The state of color is always fluid, rushing forward and gathering influences
from the world around us. We survey market, follow color forecasts of
international brands.
Total 10 designs 5 color ways each design each color below list will be
followed:

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DARK COLORS:

Black
Navy blue
Purple
Maroon
Rust

LIGHT COLORS:

Pastels
Tints

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SOURCE:
Processes that procure goods and services to meet planned or actual demand.

( Bills )RAW MATERIAL:

YARN:

Item Specs Unit Rate

Warp yarn = 40/ 2 Ne lbs 200

Weft 1 yarn = 40/ 2 Ne lbs 250
Weft 2 yarn = 150 Dn lbs 105
Weft 3 yarn = 150 Dn lbs 105

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PLAN:
Processes that balance aggregate demand and supply to develop a course of
action which best meets sourcing, production, and delivery requirements.

PRODUCTION:
The action of making or manufacturing from components or raw materials, or
the process of being so manufactured.

PRODUCTION PLANNING:

WEAVING:

1.DUPATTA:

PRODUCTION OF: DUPUTTA

Machine sulze r
loom type p7100
Jacquar d Jc4
Loom width 110”
Per loom RPM 250
Ave rage pick 67.7
No Of pa nels 2
PRODUCTION IN METERS
1 2 24
pane l Pane ls HOURS 3 0 DAYS 1 YEAR
Efficie ncy
1 loom/ pe r Ho ur 100% 5.63 11.26 270.20 810 6.06 98623.77
1 loom/ pe r Ho ur Efficie ncy 90% 5.07 10.13 243.18 729 5.46 88761.39
10 lo om/ pe r
Hour Efficie ncy 90% 50.66 101.33 2431.82 729 54.57 887613 .94

RPMX6 0 MIN/ AVERAGE PICKX3 9.36 = EFFIECIENCY

FORMULA

As per above analysis:

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 2 43.18

24 hour s pr oduction on single loom 90% e fficien cy

2 .5

1 Dupatta
9 7.27

24 hour s pr oduction of Dupa tta on single loom

0 .25

lead time(hr ) to wea ve 1 Dupatta

1 4.80

lead time(mins) to we ave 1 Dupatta

2.KAMEEZ:
PRODUCTION OF: KAMEEZ
Ma chin e sulze r
loom type p7100
Jacquar d Jc4
Loom width 110”
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 Per loom RPM 250
Aver age pick 76.91
No Of pane ls 2
PRODUCTIONIN METERS
1 pane l 2 Pane ls 2 4 HOURS 30 DAYS 1 YEAR
1 loom/ pe r Ho ur Efficien cy 1 00% 4.96 9.91 237 .85 7135.36 86813.54
1 loom/ pe r Ho ur Efficien cy 9 0% 4.46 8.92 214 .06 6421.82 78132.18
10 lo om/ pe r Hour Efficien cy 9 0% 44.60 89.1 9 214 0.61 64218.23 781321 .85

RPMX60 MIN / AVERAGE PICK X3 9.36= EFFIECIENCY

FORMULA

As per above analysis:

214.06

24 hour pr oduction of single loom 90 % efficie ncy

3

1 Ka meez
71.35

24 hour s pr oduction of Kame ez on single loom

0.34

lead time(hr ) to wea ve 1 kame ez

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 20.18

lead time(mins) to we ave 1 ka meez

3. SHALWAR:
PRODUCTION OF: SHALWAR
Machine sulzer
loom type p710 0
Ja cqua rd Jc4
Loom width 110 ”
Pe r loom RPM 250
Avera ge pick 46
No Of panels 2
PRODUCTION IN METERS
1 2
pane l Pane ls 24 HOURS 30 DAYS 1 YEAR
1 loom/ pe r Ho ur Efficiency 100% 8.28 16.57 397.67 11930.01 145148 .46
1 loom/ pe r Ho ur Efficiency 90% 7.46 14.9 1 357.90 10737.01 130633 .62
10 lo om/ pe r Hour Efficiency 90% 74.56 149.13 3579.00 107370 .10 130633 6.16

FORMULA RPMX6 0 MIN / AVERAGE PICK X39 .3 6= EFFIECIENCY

As per above analysis:

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 357.9

24 hour s pr oduction on single loom 90% e fficien cy

2.5

1 shalwar
143.16

24 hour s pr oduction of shalwar on single loom

0.17

lead time(hr ) to wea ve 1 shalwar

10.06

lead time(mins) to we ave 1 sha lwa r

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Production lead tim e of Single 3 piece s uit:

Components Le ngth Le ad time (min)

1 dupa tta 2.5m 14.8
1 Ka meez 3m 20.18
1 Shalwa r 2.5m 10.06
single 3 pc suit 8m 45.04

Counte r checking of 1 comple te suit production :

Items Le ngth pick
To tal
2.5m
dupatta 67.7 Ave rage pick
3m
ka meez 76.9
2.5m
sha lwa r 46
total 8m 190 .6 6 3.53

PRODUCTION OF: 1 comple te suit

Machine sulzer
loom type p7100
Jacquar d Jc4

1 panel Per loom RPM 250

2 Panels Ave rage pick 63.6 6
24 HOURS
30 DAYS No Of pa nels 2
1 YEAR PRODUCTION INMETERS
1 loom/ pe r Ho ur Efficie ncy 100% 5.99 11.97 287 .35 8620.49 104882.6 5
1 loom/ pe r Ho ur Efficie ncy 90% 5.39 10.78 258 .61 7758.44 94394.38

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10 lo om/ pe r Hour Efficie ncy 90% 53.8 8 107.76 258 6.15 77584.42 943943.8 2

RPMX6 0 MIN/ AVERAGE PICKX3 9.36 = EFFIECIENCY

FORMULA

As pe r abo ve analysis:

24 hour s pr oduction on single loom 90 %

efficiency(meter ) 2 58.61
1 suit in meter s= 8
2 4 hours production of suit o n single loom 3 2.33
lea d time( hr) to we ave 1 comple te suit 0 .74
lea d time( mins) to weave 1 com plete suit 4 4.55

PRODUCTION OF COMPLETE SUIT

24 HOURS 3 0 DAYS
1 lo om 32.00 960 .00
1 0 loo m/ per day 320.00 960 0.00

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Product De tails:

1.Dupatta :
Se lf Design + Weft Des ign in Borde r
3 colors insertion (weft)

Quality (dupatta) 40/ 2 x 40/ 2 x 150 x 150 x 48 x 46(67.70) = 49”

Quaity warp x weft1 x weft2 x weft3 x EPI X PPI (Avg Pick)= Width Of
Fabric

Length Total Avg 40/ 2 Avg 150 Dn Avg 150 Dn Avg

Pick Pick pick Pick pick Pick pick Pick
Specs 110” 7448 67.7 506 46 1798 16.3 1798 16.34
0 0 4
Warp = 40/ 2 Ne
Weft 1 = 40/ 2 Ne
Weft 2 = 150 Dn
Weft 3 = 150 Dn

1.Per mete r Consumption of w arp yarn(2

panels):
(Total Ends / 768.1 x warp count )+ 10% wastage
=2x(2380/ 768.1 x 40/ 2) + 10 % wastage
=2x(2380/ 768.1 x 20) + 10 % wastage
=0.3408lbs per meter per 2 panels
=0 .1704 lbs / mete r / panel

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2. Pe r me ter Consumption of w eft 1 yen (40/ 2 ):
2x (Reed space x PPI / 768.1 x Weft count ) + 2% wastage
=2x (52 x 46/ 768.1 x 40/ 2) + 2 % wastage
=2x (2392/ 768.1 x 20) + 2 % wastage
=2x (2392/ 15362) + 2 % wastage
=2x (0.144) + 2 % wastage
=2x (0.144) + 2 % wastage
=0. 2937 lbs/ meter of 2 panels
=0 . 146 8 lbs / mete r per panel

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3. Pe r me ter Consumption of w eft 2 yarns (150Dn=35 Ne):
=2x (Reed space x PPI / 768.1 x Weft count ) + 2% wastage
=2x(52 x 16.34/ 768.1 x 35) + 2 % wastage
=2x(849.6/ 768.1 x 35) + 2 % wastage
=2x(849.6/ 26883) + 2 % wastage
=2x(0.0316) + 2 % wastage
=0.0632 + 2 % wastage
=0.0644 lbs/ meter per 2 panels
=0 .0322 lbs / mete r per panel

4. Per mete r Consumption of

we ft 2 yarns (1 50Dn=35 Ne):
=2x (Reed space x PPI / 768.1 x
Weft count ) + 2% wastage
=2x(52 x 16.34/ 768.1 x 35) + 2 %
wastage
=2x(849.6/ 768.1 x 35) + 2 %
wastage
=2x(849.6/ 26883) + 2 % wastage
=2x(0.0316) + 2 % wastage
=0.0632 + 2 % wastage
=0.0644 lbs/ meter per 2 panels
=0 .0322 lbs / mete r per panel

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Dupatta s um mary:

Yarn cost &consumption per me te r:

Item unit Warp(lbs) Weft 1(LBs ) Weft 2(lbs ) Weft 3(lbs) Total cost

Specs 40/ 2 40/ 2 150 Dn 150 Dn

Dupatt a Meter 0.1704 0.1468 0.0322 0.0322

Yarn Rat e Per lbs 200 250 105 105

Yar n Cost Meter 34.08 36.7 3.3 81 3 .381 77 .5 4

Per meter yarn cost of Dupatta = 77.54

1 dupatta = 2.5m

1 dupatta yarn cost = 196.95 rupee s

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Kameez :

Quality 40/ 2 x 40/ 2 x 150 x 150 x 48 x 46( 76.91 ) = 49”

Quaity warp x weft1 x weft2 x weft3 x EPI X PPI (Avg Pick)= Width Of
Fabric

Le ngth Total Avg 4 0/ 2pick Avg 150 Dn Avg Pick 150 Dn pick Avg Pick
pick Pick Pick pick
1 40” 10768 76.91 6 440 46 2164 1 5.45 2164 1 5.45

Ingredients
Warp = 40/ 2 Ne

Weft 1 = 40/ 2 Ne
Weft 2 = 150 Dn= 35 Ne

Weft 3 = 150 Dn= 35 Ne

1.Per me te r Consumption of warp yarn:

(Total Ends / 768.1 x warp count )+ 10% wastage

=2x(2380/ 768.1 x 40/ 2) + 10 % wastage
=2x( 2380/ 768.1 x 20) + 10 % wastage
=2x( 2380/ 15362) + 10 % wastage
=2x(0.1549) + 10 % wastage
=0.3098 + 10 % wastage
= 0 .340 7 lbs / mete r

29
2. Pe r me ter Consumption of w eft 1 yarn(40 / 2):
2x(Reed space x PPI / 768.1 x Weft count )+ 2% wastage
=2x(52 x 46/ 768.1 x 40/ 2) + 2 % wastage
=2x(2392/ 768.1 x 20) + 2 % wastage
=2x(2392/ 15362) + 2 % wastage
=2x(0.144) + 2 % wastage
=2x(0.144) + 2 % wastage
=0 .2937 lbs / mete r

3. Pe r me ter Consumption of w eft 2 yarn(15 0Dn=35Ne) per 2 panels:

2x(Reed space x PPI / 768.1 x Weft count )+ 2% wastage
=2x(52 x 15.45/ 768.1 x 35) + 2 % wastage
=2x(803.4/ 768.1 x 35) + 2 % wastage
=2x( 803.4/ 26883) + 2 % wastage
=2x(0.02988) + 2 % wastage
=0.05977+ 2 % wastage
=0.0609 lbs/ meter per 2 panels
=0 .0304 lbs / mete r per 1 panels
4. Pe r me ter Consumption of w eft 2 yarn(15 0Dn=35Ne) per 2 panels:
2x(Reed space x PPI / 768.1 x Weft count )+ 2% wastage
=2x(52 x 15.45 / 768.1 x 35) + 2 % wastage
=2x( 803.4 / 768.1 x 35) + 2 % wastage
=2x( 803.4 / 26883) + 2 % wastage
=2x(0.02988) + 2 % wastage
= 0.05977+ 2 % wastage
=0.0609 lbs/ meter per 2 panels
=0 .0304 lbs / mete r per 1 panels

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kam eez yarn cons umption & cost pe r m eter

Item unit Warp(lbs) Weft Weft We ft Total cos t

1(LBs ) 2(lbs ) 3( lbs)
Spe cs 40/ 2 40/ 2 150 Dn 150 Dn
kameez Meter 0.1704 0.1468 0.0304 0.0304
Yarn Per lbs 200 250 105 105
Rate
Yarn Meter 34.08 36.7 3.192 3.192 77.16 4
Cost

Per meter ya rn cost of Kamee z = 77.16 4

1 Kame ez = 3
1 kame e z yarn co st = 23 1.49
2

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Shalwar :

Its Plain fabrics

Quality 40/ 2 x 40/ 2 x 48 x 46 = 49”

Quaity warp x weft1 x EPI x PPI =
Width Of Fabric.

Length Total Pick 40/ 2 pick

1 inch 46 46

Warp = 40/ 2 Ne wastage

Weft 1 = 40/ 2 Ne =2x( 2380/ 768.1 x 20) + 10 %

wastage
1.Per me ter Consumption of
warp yarn: =2x( 2380/ 15362) + 10 % wastage

(Total Ends / 768.1 x warp count )+ =2x(0.1549) + 10 % wastage

10% wastage
=0.3098 + 10 % wastage
=2x(2380/ 768.1 x 40/ 2) + 10 %
= 0.3407 lbs/ meter per 2 panels
32
=0 .1704 lbs / mete r per panel

2. Pe r me ter Consumption of
we ft 1 yarn(40 / 2):
2x(Reed space x PPI / 768.1 x Weft
count )+ 2% wastage
=2x(52 x 46/ 768.1 x 40/ 2) + 2 %
wastage
=2x(2392/ 768.1 x 20) + 2 %
wastage
=2x(2392/ 15362) + 2 % wastage
=2x(0.144) + 2 % wastage
=2x(0.144) + 2 % wastage
=0.2937 lbs/ meter per 2 panels
=0 .1468 lbs / mete r per panel

Shalwar yarn co st pe r meter

Item unit Warp(lbs ) Weft 1(LBs ) Weft 2(lbs ) Weft 3(lbs ) Total cos t
Spe cs 40/ 2 40/ 2 150 Dn 150 Dn

33
s halwar Meter 0.1704 0.1468 0 0
Yarn Rate Per lbs 200 250 0 0

Yarn Co st Meter 34.08 36.7 0 0 7 0.78

Per meter yarn cost of Shalwar = 70.78

1 shalwar = 2.5

1 shalwar yarn cost = 176 .95

Aggre gate d Yarn Cos t of single 3 pc s uit( gre igh):

Pe r suit
Item unit Yarn cos t s uit Yarn cos t
Dupatta 1m 77.54 2.5 193.85
Kame ez 1m 77.16 3 231.48
Shalwar 1m 70.78 2.5 176.95
Total 225.48 8 602.2 8

34
MAKE:
Processes that transform product to a finished state to meet planned or actual
demand.

WEAVING
Weaving is one of the processes that required in textile in terms of producing a
fabric. From the fiber then become a yarn through some other process, weaving is a
process of interlacing two types of yarn known as warp or ends (run parallel to the
weaving machine known as loom) and weft or filling yarn (run perpendicular to the
loom) to produce a rigid fabric.

Figure 1: Interlacement of warp and weft yarn

In order to interlace the warp and weft yarn, there are three operations which often
called primary motions are necessary:

Shedding- The process of separating the warp

yarn into two layers by raising the harness to
form an open area between two sets of warps
and known as shed.
35
Figure 2: Shedding process

§ Picking - The process of inserting the filling yarn through the shed by the means
of the shuttleless while the shed is opening.

Figure 3: Picking process

§ Be ating- The process of pushing the filling yarn into the already woven fabric at
a point known as they fell and done by the reed.

Figure 4: Beating process

To continue the weaving process, there are also two additional operations are
essential:

§ Warp control (le t-off) - The motion that delivers warp yarn to the weaving area
at the required rate and at suitable constant tension by unwinding it from the
warp beam.
§ Cloth control (take-up) - The motion that withdraws the fabric from the
weaving area at the constant rate that will give the required pick-spacing and
then winds it onto a roller.

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THEPRINCIPLES OF WEAVINGPROCESS

Yarn Re quirem ents :

Warp
§ Yarns must be strong enough to withstand greater stress and abrasion during
weaving.
§ Yarn wound onto the warp beam from single packages
§ Yen strengthened and lubricated through sizing process
§ Yarn smoothness increased through sizing materials
§ Yarn elongation and flexibility must be sustained

We ft
§ Yarn must be wound properly on a suitable package for high speed unwinding.
§ Yarn will be carried by shuttle that made up of wood which the pirn (hold the
weft) is placed.

WEAVINGPREPARATIONS::

§ Warping- A process of transfer the warp yarn from the single yarn packages to
an even sheet of yarn representing hundreds of ends and then wound onto a
warp beam.

§ Figure 5: Warping process

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 Draw-in- A process of draw every warp yarns through its dropper, headle eyes
and reed dent.

Figure 7: Draw-in process

§ Tie -in- A process of tying each of a new beam to its corresponding end of the old
beam when mass producing the same fabric.

Loom Timing:
There are two types of loom timing in weaving process which are filament yarn
timing and staple yarn timing. Loom timing is commonly in primary motions that
involve in shedding, picking and beating process. It is sensible to make the period
time of heald-shaft dwell coincide as nearly as possible with the passage of the
shuttle. There are the timing period for each of the process done in the loom. The
different between the two loom timing is the time of the dwell happen. The dwell is
refer to the maximum opening of the shed in shedding process to let the weft
inserted through it.

We aving Machine :
Weaving Machines (Loom):

Figure 8: Cross sectional of the weaving loom.

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The cross sectional of weaving loom shows the main parts in the loom and the flow
from the warp yarn inserting start from the weaver beam through weaving area and
finally the fabric done wound onto the cloth roller.

Based on the cross sectional, some process in weaving are taking place such as
shedding, picking and beating process. There are also let-off and take-up motions
take place.

The class ification of the weaving machine ry:

§ Hand Looms : This kind of loom still used relatively large quantities for the
production of all types of fabrics in the less-developed countries.
§ Non-automatic Powe r Loom: These machines are being used in ever-decreasing
numbers, especially in the developed countries, but they seem likely to retain a
certain usefulness in the production of specialist fabrics.
§ Conventional Automatic Loom: The machines that gained world-wide
popularity because of their advantages of versatility and relative cheapness.
§ Circular Loom: They are strictly limited in their applications, but they do achieve
the ideal of high weft-insertion rates from relatively low shuttle speeds because
the insertion of the weft is continuous.

Ste ps in the action of the inse rtion of warp and w eft yarns in loom to form a
fabric:

Fg 9: Steps of inserting warp and weft yarn in weaving loom

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1. The formation of shed by separating the warp yarns into two layers to create
space to allow the shuttle to passing.
2. As the shed form, the shuttle carry the filling yarn is projected through it or we
call as picking process.
3. Then, the beating take place to push the filling yarn to the woven fabric or fell.
4. The positions of the warp yarns are reversed to reform the shed and process is
repeated with shuttle travels in the opposite direction.

SUPPLY CHAIN PROCESS:

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 (SOURCING) YARN SOURCING (7-10days)

WARPING
( 1 -2 days)

WEAVING

(20-25 DAYS)

( MAKING)
GREIGH FOLDING

(2 DAYS)

SHEARING (3-4 DAYS)

DYEING
(15-20DAYS)

(DELIVER) FINISHFOLDING (2 DAYS)

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DISPATCH

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43
SUPPLY CHAIN PROCESSES:

1. SOURCING:
The term Sourcing refers to a number of procurement practices, aimed at finding,
evaluating and engaging suppliers of goods and services.

Outsourcing is a strategy by which an organization contracts out major functions to

specialized and efficient service providers, who become valued business partners.
The major reason for outsourcing is to reduce and control operating cost.

Here we have outsourced raw materials which are Yarn, Stationery, parts etc from
local market. Yarn usually comes in bags in lbs. 1 bag weighs 100 lbs and contains 24
cones of yarn.

2.TRANSPORTATION:
Yarn carries by trams/ truck to the company. It takes 7-10 days to reach. In each trip
80 bags of yarn are delivered. Later on carried by lifters to the process area.

3. MAKE:

Processes that transform product to a finished state to meet planned or actual

demand.

4 SEGREGATION AND WARPING:

After the yarn is delivered then comes the next step, Warp and weft yarn being
segregated for the usage warping process.

In weaving cloth, the warp is the set of lengthwise yarns that are held in tension in a
frame or loom. First warp is mad and then transferred to the loom for other
processes. It takes 2 days to make the warp.

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5. WEAVING:

Weaving is a process of interlacing two types of yarn known as warp or ends

(run parallel to the weaving machine known as loom) and weft or filling yarn
(run perpendicular to the loom) to produce a rigid fabric. After warping the
beam is put over the loom to start the weaving process. There are 10 looms.
Each loom produces 32 suits or say 32x8= 256 meter cloth per day. So 10 looms
will produce 320 suits or say 320 x 8= 960 meter cloth per day.

6. FOLDING:

Folding is the process of checking and mending of gray fabric. When fabric is made
on looms it is transferred to Folding department where it takes 2 days. Here the
fabric is checked thoroughly for faults.

7. SHEARING:

It is the process where extra yarn is being cleaned and threads have been cut. From
folding department the fabric is sent for shearing which we are outsourcing. It takes
3 days there.

8. DYEING:

After shearing the fabric goes for dyeing. Dyeing is basically giving color to the gray
fabric. It takes 15 days there.

9. FOLDING:

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From dyeing the fabric again comes to the folding department for final checking
before transferring it to the warehouse. It takes 2 days.

10 . DELIVER:

After transferring the fabric to the warehouse a bulk amount of fabric is delivered to
the distribution channel (DC) from where it reaches different retailers.

DISTRIBUTION CHANNEL:
It is the channel from where the fabric is transferred to the wholesaler then to
different retailers and then to the consumer. We will use Central Distribution center
with milk runs strategy. Where we will supply to a wholesaler and he will distribute
it to one of the retailer from where it gets transferred to other retailers in same and
different cities even.

FUTURE PLAN:
Our company’ s future plan is to go in forward integration i.e opening our own retail
outlet. Plus we even will try to bring all processes in-house instead of outsourcing to
save our time and increasing more efficiency. Later on other plan is to add men wear
even to our product line.

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REMARKS:

S.NO REGNO NAME PRESENTATIO REPORT MATERIAL PRESENTATIO TOTAL

N 20% 30% N STYLE 10%
40%
1 399 Maheen
2 398 Barkat
3 Tazeen
4 317 Amin
5 Tahira

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 Sign: ____________

The end of Project……….

s a New Beginning…………..
Now It’

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