WAZIR APPAREL START-UP AND RE-ENGINEERING ASSISTANCE

About WASTRA

I ndian apparel sector is passing through an important phase today. On one hand, changing
consumer trends and growing disposable incomes are leading to high demand and a shift from
tailor-made to readymade clothing. While on the other hand, Central and State Government’s
dedicated incentives for apparel manufacturing are making investments a lucrative proposition. In
the global market, China’s increasing manufacturing costs are causing it to vacate some space in
international trade which can be an opportunity for Indian exporters.
 
India’s apparel consumption is estimated to be Rs. 5.1 lakh crores while the exports are Rs. 1.1 lakh
crores (FY 2017-18). The total market is expected to grow from Rs. 6.2 lakh crores to approx. Rs. 14
lakh crores by 2025-26. Addition of nearly Rs. 8 lakh crores market would require commissioning of
more than 40 lakh sewing machines in India by 2025 – a once in a lifetime opportunity for investors!
 
However, investments alone do not guarantee success. The ingredients of success of an apparel
factory are organization, infrastructure, technology and processes. In today’s increasingly
competitive industry, one must adopt international best practices and benchmarks in local context
to establish a competitive and compliant set-up.

With these thoughts in mind,

Wazir Advisors has launched WASTRA (Wazir Apparel Start-up and Re-engineering
Assistance) to offer turnkey solution for establishing an Engineered Apparel Factory.

WASTRA team of apparel experts, industrial engineers and fashion technologists possesses
decades of cumulative experience in new factory establishment and reengineering assignments in
India, Bangladesh, Vietnam, and Ethiopia. The complex nature of fashion business needs apparel
manufacturing set-ups that are agile and dynamic yet cost effective to meet the ever changing
demands. WASTRA is aimed exclusively to deliver that.
7 Most Common Mistakes

1 Flawed Factory Design and

Machinery Layout

2 Over or Under Investment in

Technology

3 Ignorance of Modern Industrial Engineering and

Quality Control Methods

4 Wrong Hiring, Poor Training and

Overstaffing

5 Absence of Information Capture and

Communication

6 Excessive Working Capital due

7
to Poor Planning

Absence or Underutilization of
the Right Software

A
250
sewing
machines
factory can lose
approx. 2.5 lakh pieces
in production and Rs. 2.5
crore in profits every year due
to these issues.
 WASTRA Engineered Factory
A SET-UP WITH TRAINED MANPOWER, OPTIMUM TECHNOLOGY, IDEAL
INFRASTRUCTURE AND RATIONALLY DESIGNED PROCESSES

PILLARS OF AN ENGINEERED FACTORY

ORGANIZATION TECHNOLOGY
• Right organogram • Machinery selection for all departments
• Training programme for all levels • Choosing the right software
• Incentive planning • Automates and work-aids selection

INFRASTRUCTURE PROCESSES
• Building architecture • Department wise SOP design & implementation
• Factory layout planning • Setting key support functions of Quality Control,
• Utility planning Industrial Engineering, Training and MIS
• Software system implementation

KEY FEATURES OF AN ENGINEERED FACTORY

• Man-to-Machine Ratio (MMR) of 2.0 or less

• Individual operator efficiency of up to 40% within 6 weeks training
• High performance layout saving approx. 20% space compared to conventional layout
• Maximum usage of low cost automates and work-aids
• 99% cut-to-ship ratio for standard products
• Quick changeover for flexibility in product mix
• Approx. 50% lower inventory by use of lean manufacturing tools
• An effective MIS that captures right information for decision making
• Fully compliant with Safety, Health and Environmental (SHE) norms
• Line efficiency of 55 to 60% within a year
WASTRA Services

Start - Up Assistance

Establishment of an engineered factory on a turnkey basis by designing

and implementing right organization, technology,
infrastructure and processes

Re-engineering

Complete re-engineering of existing factory

to bring it closer to Wastra Engineered Factory

Tailored Modules

• Developing a performance oriented organization

• Technology optimization
• Infrastructure planning
• Designing and implementing right systems and processes
 WASTRA Differentiation

Experienced team members with global exposure

• Experience of conducting projects across the globe including countries such as

India, Bangladesh, Vietnam, Ethiopia etc.
• Team members include apparel experts, industrial engineers, fashion
technologists, MBAs, and finance experts

Experience of undertaking multiple assignments with proven success

• Successful execution of projects in factories ranging from 150 to 6,000 machines

• Diverse product exposure covering basic products like shirts, trousers, made-ups,
denims to special products including industrial wear, active wear, lingerie etc.
• Demonstrated success of having implemented turnkey projects

Robust training methodology

• Training programs at all levels

• Adoption of global best practices in local context
• Guaranteed minimum efficiency level of trained operators

Industry network
• Connect with machinery and technology providers
• Connect with software suppliers
• Running own garment operation training centres under various skill
development schemes
WASTRA Success Stories
RESULT DELIVERED
CLIENT:
Mining & Agri-business Player
• Defined organization structure
• Training of middle management and operators
LOCATION:
• Technology & software selection
Odisha, India
• Infrastructure & layout planning
PROJECT TYPE: • Defining factory KPIs with measurable mechanisms
New Factory Set-up • Development and implementation of SOPs for
compliance & sustainability

CLIENT:
Leading Indian
RESULT DELIVERED
Women’s Wear Exporter
• 24% reduction in cost per piece
LOCATION: • 39% increase in finishing productivity per person
Haryana, India • 51% reduction in changeover loss per style
• 33% increase in cutting productivity per person
PROJECT TYPE:
Factory Re-engineering

CLIENT:
RESULT DELIVERED
One of the Largest Indian
Home Textile Players
• Shift change discipline - 8% Increase in production time
LOCATION: • Method improvement & layout re-engineering
Gujarat, India • 30% productivity improvement
• 30% capacity increase by optimizing resources
PROJECT TYPE:
• 30% improvement in cutting automates
Factory Re-engineering
• 25% absenteeism reduction

CLIENT:
Leading Indian Denim RESULT DELIVERED
Manufacturer
• Creation of high performance training room
LOCATION:
Ethiopia, East Africa • Provided 300 hours of skill training
• Optimum individual operational efficiency
PROJECT TYPE: • Training of trainers for sustainability
High Performance Training
 WAZIR Clientele
70% of the clients have been with us on a continuous, long term basis and have done multiple projects with
us. We intend to grow, helping our clients businesses to grow and being their ‘trusted advisors for life’.

MANUFACTURERS
Alok Industries Ltd. Jindal Worldwide Ltd. Rieter India Pvt. Ltd.
Al-Obaidani International, Oman Kamadgiri Fashion Ltd. RSWM Limited
Arvind Ltd. Kenya Tents Ltd., Kenya Siyaram Silk Mills Ltd.
AYM Syntex Ltd. Lucy Garment Industry PLC, Ethiopia Soktas, Turkey
Bilsar A.S., Turkey Mafatlal Industries Ltd. Sonal Apparel Pvt. Ltd.
Birla Cellulose Nahar Industrial Enterprises Ltd. Soundararaja Mills Raja
Bombay Rayon Fashion Ltd. National Textile Corporation (NTC) Sutlej Textiles & Industries Ltd.
Cathay Consolidated Inc., Taiwan Nazareth Garment Share Co., Ethiopia The Rajlakshmi Cotton Mills Pvt. Ltd.
Creative Garments Pvt. Ltd. Neo Corp International Ltd. Thika Cloth Mills Ltd., Kenya
Eastman Chemical Co., China OCM Pvt. Ltd. Trident Group
Garg Acrylics Ltd. Parrogate, Zimbabwe Vardhman Textiles Ltd.
Gokaldas Exports Pvt. Ltd. PTT Global Chemicals (PTTGC), Thailand Welspun India Ltd.
Grasim Industries Ltd. Radnik Exports Wild Lotus
Indo Count Industries Ltd. Raymond Ltd. Winsome Textile Industries Ltd.
Indo Rama Synthetics (I) Ltd. Reliance Industries Ltd.

GOVERNMENT BODIES
Apparel Export Promotion Council (AEPC)
Apparel Training and Design Centre (ATDC)
Central Wool Development Board (CWDB)
Ethiopian Textile Industry
Development Institute (ETIDI)
Industries Commissioner, Govt. of Gujarat
Maharashtra State Textile
Corporation (MSTC)
Ministry of Rural Development (MoRD)
Ministry of Textiles (MoT) Tamilnadu Handicrafts
National Centre For Design & Product Development Corporation Ltd (TNHDC)
Development (NCDPD) Textile Committee
National Instructional Media Institute The Cotton Textiles Export
(NIMI) Promotion Council (TEXPROCIL)
National Jute Board (NJB) The Synthetic & Rayon
Office of the Textile Commissioner Textiles Export Promotion Council (SRTEPC)
State Government of Uttar Pradesh US Commercial Service

INDUSTRY BODIES AND DEVELOPMENT AGENCIES

African Cotton and Textile Industries
Federation (ACTIF), Kenya
Centre for the Development of Enterprise
(CDE), Belgium
Clothing Manufacturers Association of India
(CMAI)
Confederation of Indian Industries (CII)
Confederation of Indian Textile Industry
(CITI)
Cotton Council International, USA
Federation of All India Textile Manufacturers
Associations (FAITMA)
Federation of Indian Chambers of
Commerce and Industry (FICCI)
Global Fund to End Slavery (GFEMS)
Indian Jute Mills Association (IJMA)
International Trade Centre (ITC), Geneva
Intimate Apparel Association of India
(IAAI)
Okhla Garment & Textile Cluster (OGTC)
Textile Association (India) (TAI)

FASHION BRANDS AND RETAILERS

Aditya Birla Fashion and Retail Ltd. (ABRFL) Future Group Raghuvendra Rathore
Arvind Brands Inmark Retail Raymond Ltd.
Bestseller ITC Ltd. Reebok India Company
Blackberrys Manyavar Ritu Kumar
French Connection (FCUK) Me n Moms Shantanu Nikhil
First Steps Babywear Myntra Designs Study by Janka Fashions
Flipkart Perona Yepme
Team WASTRA

HARMINDER SAHNI
Managing Director
harminder@wazir.in
Harminder possesses more than 30 years of
experience in the retail, textile and apparel
consulting sector, leading a variety of strategy
& implementation assignments for clients
from more than 25 countries.

PRASHANT AGARWAL
Joint Managing Director
prashant@wazir.in
Prashant has more than 25 years of experience
with domain expertise in textiles, apparel
and skill development. He has successfully led
consulting assignments in Asia, Europe, Africa
and North America.

• Team of more than 50 apparel experts, industrial engineers, fashion technologists and subject matter
experts educated at the best in class engineering and fashion institutes.

• Expertise in factory management, training, resource planning, projects, industrial engineering, method
standardization, process optimization and software implementation.

• Assisting first time entrepreneurs as well as established businesses to set-up and operate competitive
and compliant apparel factory.
 www.wastra.in

Surender Jain Varun Vaid

surender@wazir.in varun@wazir.in
7042101333 9899985979

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Wazir Advisors Pvt. Ltd.

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