KINGS GROUP APPAREL INDUSTRIES (PVT) LTD.

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 KINGS GROUP APPAREL INDUSTRIES (PVT) LTD.
TQM

KINGS GROUP OF
INDUSTRIES (PVT)
LTD.
Quality Assessment

Ahsan Waseem
Shahid Aziz Sheikh
Waqas Ahmed

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KINGS GROUP APPAREL INDUSTRIES (PVT) LTD.
Introduction

Kings Apparel is a vertically integrated knitwear production company, which was

incorporated in 1988. It is a core business concern of
Kings Group. The Group owns an IATA travel agency;
Ace Travels. It is also the sole franchisee for United
Colors of Benetton and a project and investment
partner in a number of commercial and educational
developments.

Kings Apparel has established a tremendous presence in the International markets

especially in Europe and the United States. We supply to major clothing brands and large
buying houses. Our manufacturing facility has an in-house production capacity of 8 million

units per annum and exports 100 % of its output.

The company is one of the biggest exporters of knitwear and clothing in Pakistan. We have
received the ‘Best Export Performance Award' eleven years consecutively in volume or
turnover for different categories of the product. They produce the highest quality garments
and our entire organizational and production processes are equipped and continuously
updated to satisfy our buyers. Kings Apparel is an establishment and we care about our
reputation and our future.

Other Companies of Kings Group

Ace Travels

Ace Travels is an IATA agency and a tourism company. Our business is

focused on the corporate sector and we discriminate on the platform of
our service and knowledge of international travel. Our management
team comprises of people with many years of aviation industry
experience. Ace Travels leverages remarkably from their experience
and positions to provide better service. Ace Travels is located in the hub of the travel
industry in Karachi and within a mile of the commercial and business center of the city. We
are online with global reservations systems and invest continuously in technology. We
generate an average turnover of Rs. 200 million per year.

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The Company also represents Air Macau and Surinam Airways as their GSA for
Pakistan through its subsidiary company.

United Colors of Benetton

Kings Group acquired the franchise for United colors of Benetton in

1995.
It was the first foreign designer clothing brand in Pakistan and
consolidated the Group's reputation in the domestic and international market.

They have a number of retail outlets in Pakistan's major cities including Karachi,
Lahore and Islamabad.
Plans to manufacture Benetton Clothing in Pakistan under license in our own manufacturing
facility are underway.

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KINGS GROUP APPAREL INDUSTRIES (PVT) LTD.

Products

The company manufacture knitted readymade garments for Men, Women and Children in
solids, prints and yarn dyes, etc. Garments are made in 100% cotton, blended fabrics,
poly cotton of different blends and rayon in different qualities. Some special fabrics, like
polar fleece, micro polar fleece and velour can also be imported according to
customer's specifications. We manufacture standard styles, fashionable styles and value
added styles according to need of our customers.

The fabrics we normally work with are jerseys, piques, ribs, interlock jacquards (full &
mini), pointelles, engineering stripes, French terry, flat back ribs, herringbone,
velour, loop terry, fleece, sherpa with finishes like brushing, peaching,
enzyme/silicon wash, etc. Most of these fabrics are also produced with mmLycra
additions. Major share of our exports are in men's tops, women's and children's wear.

Production and Manufacturing

Knitting Facilities
The company has in house Knitting, Fabric Dyeing, Printing, Embroidery, Stitching
and Washing facilities. Each department is managed by a team of production experts
with specialist knowledge and experience of many years in that department. All

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KINGS GROUP APPAREL INDUSTRIES (PVT) LTD.
departments communicate and liaise effectively along the sequential production process.
Each department comprises of many units, which are centrally organized to improve
efficiency and reduce slack. Our experience in management of this business continues to
deliver excellence in quality at competitive prices and timely delivery of orders.

Knitting

the latest knitting machines from Pai Lung and Fukuhara are installed in this state of the art
facility. These machines are equipped to produce Jersey, Pique, Fleece, Interlock,
popcorn, Twill, Herringbone, all 4 cam structured fabrics and Rib in addition to
mini Jacquard designs in Single Knit Jersey. The gauges range from 20 to 32 for Single
Knit jersey, 18 to 28 for Interlock and 15 to 20 for Rib machines. The facility has a capacity
to knit 6000 kgs per day. Most of the machines are equipped to knit with Lycra additions.
In addition to the circular machines, there are 6 flat knit machines, which produce welt
collars and cuffs.

The knitted fabrics are thoroughly checked to ensure that only “A” grade fabric is
transferred to the subsequent operations

Dying Facilities
The fabric-dyeing department in Kings Apparel has a capacity of dyeing, bleaching &
finishing 15000 kgs per day. It is equipped with the latest Fongs high temperature and
atmospheric dyeing machines, superior Santex open width and as well as tubular fabric
finishing line with the latest tubular tube-tex shrinkage control compacting machine
and open width Lamperti raising machine.The dyeing unit is capable of dyeing both
100% cotton and blended fabric with varying machines capacity from 100 kgs to 800 kgs.

Stitching facilities
The apparel stitching department in Kings Apparel has the capability of producing
600,000 pieces per month and is equipped with high-speed Pegasus, Juki, Yamato
and Subaro machines. The stitching work is carried out in 10 independent stitching
units, each equipped with team of cutting masters who use technologically advanced
software and a dedicated sampling unit.

Experienced managers supervise skilled teams in each unit to complete the final packing

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stage once garments are ready. Strict quality control checks are employed at every stage of
the processes and separate quality control teams look after each unit .

Embroidery facilities
Kings has stepped up appropriately and aggressively to fulfill the value added garment
requirements of its international buyers. Our embroidery department has recently been set
up by making substantial investment to acquire fully computerized, high-speed Barudan
embroidery machines known for efficiency and quality. Each machine has 20 heads
and can embroider in 9 different colors

Printing facilities

Kings printing department is equipped with Hi-Tech 8 colours Schenk Spider printing
machines and with the latest Hix printed paper heat transfer machines and as
well tables of manual screen printing. Kings printing is equipped to meet almost any

printing requirement in-house.

Customer

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Organic Cotton
Kings Apparel launched its Organic Cotton project in January 2000. Today Kings Organic
Cotton project yields 80,000 kg of organic cotton lint and supplies Garments made of
Organic Cotton to customers in Europe and the United States in accordance with their
special requirements.

Location
Winder a small village 72 km from Karachi in the fertile Las Bela district in the province of
Balochistan was chosen to grow organic cotton. The village is accessible from Karachi by a
major highway. The land was mostly virgin but fertile. Today cotton of the highest quality is
grown on 3000 acres of land cultivated on the principles of organic agriculture.

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Growing Organic Cotton
The project is supervised by Mr.Tadeu Caldas, Chief Consultant of ECOTROPIC, an Organic
Agriculture Consultancy based in Germany. The project has been certified by Ecocert
International.
The company partners 40 local farmers in the production of organic cotton. These farmers
are evaluated for their suitability and induction into the program. Historical records of the
cultivation of their land are assessed and status of the land is determined. The farmers are
trained continuously and our agricultural scientists work with them throughout the year.
Onsite laboratories in Winder rear the organisms required for healthy crops and monitor the
quality of cotton.

Community and Social contribution

The production of Organic cotton limits the long term damage to the earth and
environmental contamination is reduced remarkably. This directly nurtures natural habitat
and improves human health in the region.
Kings Group has adopted the community of Winder and is directly involved in its welfare.
Green Source Kings Primary School has been set up by the company in the centre of Winder
to educate the children of this rural far flung village. A model farm trains young farmers in
the science of organic cotton production and the techniques of modern agriculture

Industry Organization Certificates

➢ ISO 9001
➢ ISO 14001
➢ OHSAS-18001
➢ OEKO-TEX STANDARD 100
➢ WRAP (World Wide Responsible Accredited Production)
➢ SA_1000
➢ OHSAS_18001
➢ GOTS- Global Organic Textile Standard

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KINGS GROUP APPAREL INDUSTRIES (PVT) LTD.

Contribution towards Quality

Kings Apparel Industries (Pvt.) Ltd. is an ISO 9001, ISO 14001 and OHSAS-18001 certified
company. We are proud to have successfully supplied to leading brands such as Sears,
Target, J.C. Penny, Wal-Mart, ROX, C&A, JOMA, Mango, and Zara amongst many others
and have maintained excellent quality standards throughout. Our quality control systems
have also contributed towards improving the efficiency of our production lines. Thus, we
have been able to supply the quality merchandise at
competitive prices in the international market.

The Quality Control department has high priority and infiltrates

all sections and all production units at all stages of the process
collaborate with it.

There are quality checks at every stage of manufacturing, starting from Yarn selection,
knitting Fabric, Processing, Cutting, Stitching and Packing. Before the fabric is cut, it is

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checked thoroughly to confirm that it meets the standards of
shrinkage, color fastness, finished gsm etc. After cutting, all
cut panels are inspected to ensure that only the good quality
pieces move to the stitching units.

During the process of sewing, each and every process is

inspected by inline inspectors. The inspectors make sure that
only good parts move to the next stage. An individual tracking number is affixed inside all
parts of the garment to control the size and shade. After trimming and pressing, highly
experienced final inspectors inspect each garment. The Quality Control team monitors the
performance of every individual inspector by picking up the inspected garments and
checking the quality of these garments.

To ensure that the garments are packed as per the requirements a separate quality
inspection team checks and verifies the final packages before shipment.

Our quality control systems are not restricted to production. We adhere to quality in the
fulfillment of all our social and legal obligations and work towards continuous compliance
and implementation of National and International Labor, Health and Safety and Environment
Pollution standards and regulations.

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KINGS GROUP APPAREL INDUSTRIES (PVT) LTD.

Leadership

Senior Executives provide leadership by giving authority to concerned quality managers (GM
Quality Assurance) for planning in providing quality goods, and they are also given
responsibility for ensuring quality value are adhere outside the company. Quality values are
clearly defined both internally and externally, the employees are given clear instruction
about maintaining quality through formal written procedures, the Kings Apparel Co. is
basically customer driven company the general quality standards are defined by the
customers. The structure of the organization is such each department goes under quality
checks such as in manufacturing department, starting from Yarn selection, knitting Fabric,
Processing, Cutting, Stitching and Packing. For addressing nonconformance issues the
company has laid down a procedure for Non-conforming product. The procedure involves
incoming stage, in-process stage, and final inspection. For evaluating and improving
awareness of use of quality values the company provides training related to quality and
periodic quality inspections are down. The company is ISO_14000 certified and complies
and implements of National and International Labor Laws, Health and Safety and
Environment Pollution standards and regulations, company has also established a plant for
waste management.

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KINGS GROUP APPAREL INDUSTRIES (PVT) LTD.
Management review meetings normally held once a year but can be arrange on excess of
nonconformance or any other important issue.

Meeting agenda include:

➢ Follow-up Action from previous surveillance Audit

➢ Next Surveillance Program
➢ Business arising from previous meeting.
➢ Maintenance of the ISO 9000 / 14000 program.
➢ Results of internal audits.
➢ Corrective & preventive action requests.
➢ Customer Feedback &complaints.
➢ Review of Quality / environmental Policy and Quality / environmental
Objectives

Information and Analysis

Department In charge is responsible for entering correct data in the formats. These in
charges are responsible for any omission and data manipulation. The Department heads
then approves the records. The summary of each record is then analyzed by the responsible
personnel. Data, collected for statistics will be reviewed by the GM Production and QA
Manager. If there is any delusion in the data, Production Manager and QA Manager are
responsible for reporting to the GM Production. Kings Apparel Co. uses customer data,
specification regarding how to evaluate their quality requirements, what procedure they
adopt, in terms of finance they compare against cost benefit using modern technology for
continuous improvement. The company uses statistical techniques to examine the records,
they have close relationship with buyer and suppliers, and the data collected from buyers
and suppliers is cheeked through statistical models, and the data is accessible for both the
parties. Company improves their performance by adopting new methods which reduces
cycle time. The buyers are so giant as far as competition they are not any rivals or
competitors (Supplier Captive), they give limited consignment to every suppliers. In order
to set benchmarking the adopt customer card approach what every the customer wanted
they create benchmark accordingly. Company establish their performance by eliminating
waste by corrective actions, such as a machine stops there is stand by machine as a back
up.

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Strategic Quality Planning

Company is more focusing on both future and present customers by fulfilling their
requirement, through setting benchmark adopting the core competences, as far as
technological advancement is concern the company adopts moderate technology, the
machines used in the company

➢ Single Needle Lock Stitch

➢ Over Lock
➢ Flat Lock
➢ Bar-tacking
➢ Button Attach / Hole
➢ Shaper Machine
➢ Steam Iron
➢ Tape Cutter
➢ Kingree Machine

The company has strict policy for aligning of subunit activates, and it is controlled and
monitored through cycle time because each subunit depend other unit for completion of
work, each unit assigned a cycle time and the activities are further coordinated by subunit
managers and GM QA.

Company has policy of MBO (Management by Objective) through which they continue to
improve the planning process as well as solicited through company suggestion box through
which they get complaints in order to settle down the problems if they occur in the
organization, the company focus on apparel manufacturing as niche marketing which is the
requirement of the customer.

Company gives training for employees who require training, such as maintenance of
machinery, giving learning opportunities to operate modern machineries. They send their
employees to international workshops for quality planning process.

Human Resource Development and Management

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When excessive non-conformance or quality problem occur, training is identified for
employees by the management. The Departmental Heads of the concerned Unit will assess
training of Employees at the time of Hiring. The company strives to continually personnel
practice and monitor through Quality System Training, the courses contain an overview of
the Quality System, The Kings Apparel’s Quality Policy, the quality elements and how this
affect their jobs, and their responsibilities for maintaining and improving the quality system,
regarding promotion policies the company promotion are give experience bases after a
certain time period as well and according to the performance, employees are sharing
responsible and empowerment in decision making and suggestion box for any improvement
or any innovative idea. A training program is scheduled six monthly i.e. in the month of
February and August prior to the surveillance audit. Arrangements of all the training
programs are made by the Management Representative. Company evaluate employee
performance on the bases of completion or achievement of goals assigned and some
employees may requires re-training if these are substantial qualities are product related no-
compliance that trace back to particular employee through quality and performance
objective method company gets recognition in terms profits.

Working Environment Conditions Floor Scheduled sweeping and mopping is performed

by sweepers to keep the production floor clean and sanitized. Separate Washrooms are
provided for male and female workers, and they are respectively marked so. Fire Alarms
and Fire Extinguishers are made available in numbers, in case of fire. Also Evacuation Plans
are posted in the production units for safer evacuation of all the employees. Racks Each
department on the production floor is provided with Racks to store any / all required
product items during production. This practice helps avoiding any damage / deterioration of
the product and product items. Trolleys Production floors are provided with the trolleys, to
meet cartage requirements of fabric, trim and accessories from one department top
another. Bins are provided on proper places throughout the production floor. This confirms
that cutting wastage, sewing wastage, and all other waste is dumped in proper manner.

Proper ventilation is ensured by providing windows on the walls at the proper distance
throughout the production unit floor Lighting Conditions all the production units are
provided with the sufficient lights. Each final checker is provided with an individual tube
light, over his / her table. Floor has the Emergency lights in case of power failure.

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Management of Process Quality

Customer and quality requirements are addressed through a control process, the process
involves Production planning; in which Sample request is sent to sample department,
through Merchandising Manager. The sample request is sent with all the specifications and
requirements of the buyer. The company maintain quality of process in accordance with the
inspection, testing and internal audits. Company has rigid process and needed to work on in
improving the process the product design. The company analysis’s the product and service
data by comparing it with previous performance for continuous improvements. Company
makes purchase from approved suppliers, suppliers are provided with original artwork
sample to make accessories as per requirements, and the company communicates its
suppliers for quality requirements by providing them detailed specification of raw material.
The company monitors supplier’s performance through the process of “suppliers evaluation
form” and according to that they provide feedback to suppliers. The relationship with
suppliers is of one off and depends upon the quantity of consignment the yarn is rather
produce or purchased from the outside sources.

Quality and Operational Result

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KINGS GROUP APPAREL INDUSTRIES (PVT) LTD.
Company documents current level of performance on all key measures like accuracy,
timeliness, after sale services. The documentation is done through a process in which
detailed description about number of employee on each operation, their performance and
quantity of raw material used of each task. Key indicators for quality and performance are
done through the number of units prepared and the amount of wastage of raw material.
Documentation of supplier’s performance is done suppliers evaluation form and comparing
the past performance of the suppliers. The company compares the supplier’s quality in
different phases; the process includes keeping a thorough check at each stage of
production. Yarn is inspected if any problem or defect found yarn manager immediately
arranges the replacement from the same or any other approved supplier. Complain for the
defected yarn is recorded in complain book by the yarn manager for future agreements,
company documents data of past several years for maintains and improvement of quality
measures. Following is procedure for documentation

Document Maintenance

Computer backup will be maintained for all the level of Kings Apparel’s QMS (Quality
Management System) documentation.

Control of Specifications, Standards, Drawings

All Specifications, Studies, Drawings are received and kept by the concerned Merchandiser.

Merchandising Manager sends the Production file, If necessary original Specifications,

Studies, Drawings are sent to the concerned department than the concerned Merchandiser
keeps track by appropriate means all Specifications, Studies, Drawings are retained. All the
production / environment related documents which are not included in the QMS and EMS
documentation but indirectly affecting the product / environment is circulated with control
stamp on the front.

Documents from External Origin such as buyer’s standards, AQL Levels (Acceptable Quality
Levels) etc are controlled by placing a “controlled copy” stamp at the front.

Customer Focus and Satisfaction

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KINGS GROUP APPAREL INDUSTRIES (PVT) LTD.
Kings Apparel co has a strong understanding of attributes’ product and services that satisfy
basic customer needs, they have improved their relationship with their customers by
improving and maintaining the quality standards, recently they have successfully completed
the sample consignment of Addidas of 10000 T-shirt, and got a “Green” in evolution of Wal-
Mart audit, they have clearly define roles for personals dealing with customer contact
persons by giving them full authority for managing resources and have full cooperation from
the top executives, the company has given full accessibility to its customer by providing
customer feedback form, the form helps in dealing with problems that arises related to
customer satisfaction (The form is more quality conscious and as per customer satisfaction).
Company has made its own customer services standard for dealing with customer, they try
their utmost to resolve the problems effective and efficiently. The policy related to hiring of
personnel related to customer contact persons has extreme importance because in business
like this their times when only these person bring the customer (Buyer) for the company,
and ensured that they have full commitment, customer satisfaction is also measured
through the renewal of contracts, they have made their completive advantage in market
through the usage moderate technology in apparel industry.

The company maintains effective communication with customer by adopting the procedures
which involves following steps:

Communication

Merchandising managers communicate with the customers for orders, approvals and others
business related activities.
The Managing Director also communicates with the customer (if required).
All the communication is done through faxes, e-mails, telephone and courier.

Feed back

Customer feed back form is send to all customers on yearly basis by the Managing
Director/Merchandiser to get their feedback.
All forms send to customers are recorded in a log sheet
On the receipt of customer feed back it will be discussed in the Merchandiser meeting for
the improvement and betterment of the system.
Customer feedback is taken against:

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Product quality
On time delivery
Communication information
Complaints
(Feedback can be taken on other quality / performance related matters if required.)

Graphs

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Leadership

Information and Analysis

Strategic Quality Planning

Human Resource Development and Management

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KINGS GROUP APPAREL INDUSTRIES (PVT) LTD.
Quality and Operational Results

Customer Focus and Satisfaction

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KINGS GROUP APPAREL INDUSTRIES (PVT) LTD.

Kings Apparel Industries (pvt) ltd scored 599 points out of the total of 1030:

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Index No. Content Pg No.

1 Introduction 2-3

2 Products 4

3 Customer 5

4 Organic Cotton 6

5 International Organization Certificates 7

6 Contribution towards Quality 8-9

7 Quality Assessments

8 Leadership 10

9 Information and Analysis 11

10 Strategic Quality Planning 12

11 Human Resource Development and Management 13-14

12 Management of Process Quality 15

13 Quality and Operational Results 16

14 Customer Focus and Satisfaction 17-18

15 Graphs 19-22

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