Overview of Company Profile:

 Company Name/ Address

• Started in 1974 at Faridabad, in Delhi
• Bangalore operations began on 1st November 1988 with 250 associates and 104 machines.
• Expanded over 200 times from last 30 years
• Manufactures 3 million pieces of high quality woven’s & knits per month
• In-house product development and design studio
• Uses 3 software platforms such as MOVEX, COGNOS and OPTITEX.
• Major business operations are Textile Mills and Apparel Manufacturing.
• Future plans: set up 3 more units in Karnataka, plans in Bangladesh and Pakistan.
• Competitors: Madura Garments, Gokaldas Exports and VK Exports.
• Key personnel:
• MRS. SARALA AHUJA - Chairperson(founder)
• MR. HARISH AHUJA - Managing Director
• MR. GIRISH AHUJA - Director
• MR. SUBHASH TIWARI

• MR. RAMALINGAM

 History
Shahi exports Private Limited started its journey in 1974 with a unit in Delhi. Operations in
Bangalore began on 1st July 1988 with 250 associates and 104 machines. The journey still
continues opening its plants in Shimoga and Tirupur keeping in mind to become a self-
integrated Company keeping an eye on quality, starting from yarns to final garments.
Shimoga plant is a recent addition to the company portfolio. It is a spinning unit whereas the
Tirupur plant is a knitting unit. Shahi exports today is one of the leading export houses in the
world. The company has expanded more than 60 times in the last 38 years. In Bangalore
itself they have two units, one in Sarjapur Road which concentrates on woven whereas the
other is in bannerghatta road, which is a knit division.
 Overview
The unit manufactures more than 3 million pieces of woven and knits per month catering to
all segments in the apparel industry. The manufacturing units are located in Delhi,
Bangalore, Tirupur and Selem. The entire Shahi organization works on Enterprise Resource
Planning System (EPR system), which unifies all department’s working. This system allows
typical handling of manufacturing, distribution of inventory, shipping, invoicing and
accounting. It also synchronises business activities like sales, delivery, billing, production,
inventory and quality management and also human resource management.
• MR. HARISH AHUJA - Managing Director
• MR. GIRISH AHUJA - Director
• MR. SUBHASH TIWARI
• MR. RAMALINGAM

 Company Vision
Aim
Their aim is to attain high score on customer delight index by understanding customer’s
values, expectations and striving to achieve the same.
Vision
 “Be the global best in bringing delight to human life by weaving dreams of fashion & feelings
of comfort”.
Mission
Be the most preferred competitive global supplier of apparel. – Be the most preferred
employer in the industry. – Be a learning organization to improve & excel.
Values
Customer delight. – Integrity & ethics. – Respect for human values. – Nurturing human
talent. – Continues improvement

 Organizational Structure

 Infrastructure

Fabric store
Fabrics procured are stored in the store room. The fabrics are procured in bulk on the basis
of the order and are kept in huge open racks differentiated by the name of the buyers
handled by the export house. The excess/ left out fabric after production is then again
bought to the fabric store which can be used by the design and development team.

Washing
The unit is the largest setup of Ramsons with a capacity of 25 to 50 kilograms with water
level indicators, temperature control devices on the machine. There are 3 garment dyeing
machines whereas the rest are bit dyeing machines in the main washing room. Every
production floor has a small washing section separately to remove stains, etc. from the
garment. Different washes change the look of the garment/fabric.
The major difference between the two washes is that bit washing is done prior to the cutting
and stitching of the garment while the other is done after the whole garment is made which
means the next step is tagging and packing. One wash can be given at bit stage whereas
another completely different wash can be given at the garment stage to achieve a look if
required.
Washing is of two types. They are:
1. Dry wash
As the name itself indicates “dry” which means here water is not used. This is usually done
to give certain effects on the garment. Such washes are more used on denim and jean
fabrics. Example: stone wash, sand blasting, grinding, etc.
2. Wet Wash
In this method water is one of the main ingredients used for washing. This is done to check
shrinkage, remove stains, dirt, pencil marks, etc. enhances the feel of the garment and also
to provide required effects on the surface of the garment. Such washes are widely used for
all sorts of garments. However, the type of wash depends upon the nature of fabric, buyer
requirement and specifications.

Spreading, Cutting, Sorting and Bundling

In spreading department fabric lays are laid manually as per the marker length, at the end of
the lay the workers cut the fabric with scissors and end cutter. During spreading they take
care of shades in the lays of fabric; they do check the width and length of the fabric and give
report. They maintain a report of how many layers are been lay and the laying being done by
whom. To get perfection during lay cutting in case of checks and stripes fabric the lay cutters
do follow the design and then cut it o, but in case of plain fabric they cut the fabric as it is.
They are getting more end bits during spreading but they use these end bits to cut garment
parts. In certain cases, 2 end bits are joined together to make the required length. This is
possible if shades of both the end bits are matched.

Cutting is very important and necessary process without which the garment can’t be
stitched. Cutting should be done according to the marker & is carried out by cutting master.
The cutting department receives the checked fabrics and is then cut into rectangular blocks.
It is then sent to the sorting department where the fabric is relayed using pins and then is
cut with the help of band knife machine. The cut parts of the same size are bundled together
and are tagged accordingly. After the fabric is cut perfectly, it is sent for ticketing. Each and
every cut piece is ticketed and bundled. In case of cutting fusing/interlining, the fabric is
spread on the spreading table and the patterns are laid over the lay, and then the fabric is
cut. Six operators are required to complete this procedure, 2 for sorting and arranging the
fabrics according to the numbers, two for moving the fabric on the table and two for moving
the fabric and cutting fusing by fusing machine. There are quality checkers who check the cut
parts and record defects found in the bundles.

Printing unit
Shahi exports, unit 12 has its own printing department. Printing of both production and
design development team is done here. It has the latest printing facilities which can produce
90,000 meters a day. The unit also has its own screen making lab and colour lab. The printing
department has 8 screen printing machines with different screen capacity. 5 of them are 8
screen machines whereas 3 are12 screen, one of which is an automated machine. The unit
has a workforce of 79 workers approximately. These machines are used for production
samples. Development samples are printed manually by the workers.
Embroidery Department
Hierarchy
Asst. Manager
Embroidery Executive
Shift In charge
Supervisor
Operators, tailors and helpers
There are 2 embroidery units in Shahi exports, unit 12 in respective buildings. There are 14
embroidery machines in totality. 3 of the machines have 20 heads each whereas the rest
have 18 heads. Shahi is one of the largest installations of Barudan with all the embroidery
machines of the same. Embroidery for both production order and sampling happens in the
units.
Every machine has a main head which helps operate the 20 or 18 heads of the machine. The
main head acts like brain of the machine. The -oppy is inserted into the head with the design
pattern. Design pattern is nothing but the path assigned to the needles. The data is read as
movement of every needle and transferred to different heads. Every head has 9 needles and
has a bobbin attached at the bottom of the machine help forming stitches or loops. The
embroidery table has a bed moving bed which can be adjusted as required. It has automatic
stop mechanism if some problem comes, if thread breaks, etc. The machines are capable of
producing 9 colours producing 1 billion stitches in 1 day.
These also have checking tables and marking tables where operators check for defects and
mark the placement of the embroideries if any. Also, the unit has Single needle machine for
alterations in the embroidery design. For example, during trimming some threads break and
affects the design then, tailor would add stitches with SNLS machine. Defects are marked by
a red arrow sticker and are then forwarded to the tailor who then alters it. Embroidery
pattern is sent to the head of the embroidery department who first checks the design
keeping in mind the possibilities of the embroidery machine and then forwards it to his co-
worker who converts the design into the movement of the needles. The design sent in PDF
format is first converted into a JPEG image and is then traced using software’s like Optitex or
Wilcom E5-65 designer where the stitches are made defining the movement of needles.
There are different colours with names as 1, 2, 3, etc.
Embroidery unit works in 2 shifts which run till 9 at night. Embroidery unit has 1 assistant
manager, 1 embroidery executive, 2 shift in-charge employees, 1 supervisor and
approximately 60 workers which include operators, framers, feeding helpers, trimmers,
checkers and tailors.
Types of frames
There are 4 structure of frames used available in Shahi exports, Unit 12 with different sized
diameter as 19mm, 15mm, 9cm, etc.
• Circular / Ring frame
• Rectangular frame
• Spider frame
• Blank frame

Hand Embroidery
Though hand embroidery is expensive, it is still done in Shahi as it has its own grace.
Embroidery units for production and design development team are different, but the
procedure followed by both of them is the same.
As soon as the embroidery executive (masterji) receives the artwork, he passes it to his
workers for punching. Punching is to replicate the artwork on gateway sheet in the form of
holes with needles. All type of hand embroideries as well as embellishments are possible.
Thread tassels, sequins, etc all types of hand works are done here.
The department also train interested employees from other departments like stitching, etc
(if that department have excess) as well as trainees and picks up the best whereas sends the
others back to their respective departments.

Segregation and Dispatching

The garment from batches after button section is segregated and dispatched before or after
washing as per the sizes and shades to different batches for further finishing and packing
processes.

Trimming
After washing the garments are subjected to trimming section. In trimming loose threads are
cut with the help of a trimmer. Inside and outside trimming is done on the garment. At the
time of trimming care should be taken that it should not affect the stitches in the garment or
the garment.

Finishing
Finishing is done before packing. It is been carried out before or after washing as per the
buyer requirement or dependent on the fabric. The garments from the production section
are sent for washing by segregating them on the basis of sizes, shades. The main objective of
finishing is to finish the garment as per buyer requirement and present more effectively.

Inside checking
The outside of the garment is checked to note if there are any defects in the inside of the
garment. A sticker is pasted inside the wash care label at the time of inside checking.

Outside checking
In outside checking, the outside of the garment is checked like parts of the garments, its
position, buttons, line matching etc. These are checked based on buyer identifications. If
there is any defect in the garment or in any part of the garment, a sticker is placed over the
defect. If possible that part is changed or altered. If replacement is not possible or if stain is
not removed in washing, the garment will be rejected. The pieces are again trimmed and
checked if any alteration has done on the garment. The method of checking is changed
according to the style of the garment. The garment is then placed in the thread-sucking
machine. All the trimmed threads and dirt are removed.

Ironing
After Trimming and Checking, the garment is sent to ironing section. First the buttons are
attached and then the garment is ironed. The steam is connected with the pipe to the steam
iron box. Ironing is done in two stages rough ironing and final ironing.
Rough ironing is helpful for the identification of defects. After ironing the garment is
measured and put on hanger, if required folding is done. Ironing, folding depends on the
buyer specifications.
Packaging
Packing is the final stage of garment industry for shipment of goods. The main objective of
packing is easy transportation of goods. It is also done to maintain the quality norms of the
garment. Packing of the garment is done depending on the requirement. If the garment is
hanger packed, put the size clip on the hanger. The size clip helps to identify the sizes easily.
Then the tag or main label is attached with the hand machine. The place where the tag is to
be attached will depend on the buyer specifications. Then the garment is placed inside the
polybag. The Size ratio in a bundle will depend on the purchase order. According to the size
ratio, bundles are placed inside the carton. In the purchase order, the number of bundles
that should be contained in a carton will be mentioned. Shipment case number is put over
the carton; all other details are printed over the carton. The company auditor checks at the
time of packing and accepts the garment based on the purchase order. Then the buyer’s
auditor will further check and accept the goods. Then the shipping is done.

Product Development Process ( followed by the company)

According to me, the procedure of working in Shahi Exports Private Ltd. can be understood
in two categories. One of the categories concentrates on the marketing team whereas the
other on the design development team. All the departments of the company are directly or
indirectly related to both the categorized departments which serve as a link between the
same like the printing unit, embroidery unit, purchase department etc.

Marketing Team
The work process of the marketing team starts at the point of receiving an order from the
buyer. This order comes in the form of a tech pack which constitutes every minute detail of
the garment. The tech pack has construction details, measurement details, fabric details,
embroidery or printing or any other embellishment details (if any) and also has trim details.
It is the responsibility of the merchant to co-ordinate with the buyer for the style. Here
designer’s role is to support the Design related queries of the respective marketing team
that they are attached to.

Sampling, Production and Shipment

There are many samples made during the procedure and are approved simultaneously. The
samples include Proto sample, Co-ordination sample, Fit sample, Pre-production sample
which after approval goes into actual production. Simultaneously fabrics, trims (if any), are
sourced and kept in the fabric store and accessory store respectively. Finally, after the
approval of top sample the Company gets the right to shipment.

Design Development Team

The design development team constitute Designation Manager and Designation Senior
Executive Design who are further divided into teams which are answerable to their
respective heads. The team I worked with had Ms. Deepti as the Design Manager whereas
Mr. Noah as the Senior Executive Design. They handle the Design and Developments for all
 the buyers that their marketing team handles and are answerable to Ms Tiru, DMM for the
marketing team.
The Design Team work includes offering new artwork proposals of the selected buyer styles
and also key trend developments as per the latest trend spotting from across all fashion
sites, blogs, WGSN, magazines and buyer trends. The developments are then shown to the
respective buyers by the respective designers. The role of merchant comes into picture for
doing the costing and handling the production of the selected samples and the same
procedure is followed as in the Marketing team.
Both design team as well as Marketing team has the same fabric store, pattern master, CAD
unit, embroidery unit, printing unit, purchase unit and also the merchandising unit to some
extent. Therefore, these departments are linked with each other as their working
collaborates.

Process Flow
Fabric procured from fabric store
Fabric issued for cutting
Fabric spread and laid
Fabric is cut
Parts sent for embroidery/printing, etc
Quality check
Bundling

 Production/Manufacturing Capacity
Industry has around 1,25,000 knitted and woven Garment units. Production capacity is 8,390
million pieces, in which 1,930 million pieces are exported. All woven division is having
capacity of manufacturing 3 million pcs/month. Around 12,000 tons of fabric is being
sourced per month for manufacturing the pieces. It has 127 production lines, all are the "cut
to pack" with 2,600 sewing machines whereas almost 70,500 cuts per day have been
executed using 127 cutting tables. Among the regular buyers every season in which 60% are
USA buyers and 40% are UK buyers. Shahi is fetching the major business from Tommy
Hilfiger and Kohl’s. Over 36.5 lakhs workers are employed in Shahi. US and Europe are the
main import hubs.

 Market Coverage
The company has grown from leaps to bounds from a simple fabrication unit to present
turnover of Rs. 2200 crore, around 55000 employees and spread over 27 locations. It has
manufacturing units in six different states of India viz. Delhi, Haryana, Uttar Pradesh, Tamil
Nadu, Karnataka and Andhra Pradesh. The group is into manufacturing of a wide range of
Men’s and Ladies wear and also home products. SHAHI group has all the modern units
equipped with state-of-the-art technology giving the best to its buyers.
 Brand Architecture 
 Identity Statement
Shahi considers the quality as strive to delight customers through Lean Manufacturing
System with respect for human values.
•100% delivery on time in full (OTIF)
 •Reduce manufacturing cost by 10%
•Reduce material wastage by .5%
•Become preferred employee

 Brand Positioning
Within a time, span of almost 20 years Shahi exports has developed a prole with 100+ U.S.
and European buyers. Shahi exports Pvt Lt. caters to all categories of clothing in terms of
men, women as well as kids. Unit 12 specialises in tops or say t-shirts therefore, they usually
don’t take orders for bottoms. Some of the buyers are:
 H&M
 Marks and Spencer’s
 Ann Taylor
 Monoprix
 Tommy Hilfiger
 Gap
 Matalan
 AEO
 UCB
 Walmart
 Decathlon
 J. Jill
 Kohl’s
 Abercrombie and Fitch
 LOFT
 C&A
 Sonoma
 Yessica
 Zara
 C&A etc.
 Brands under my mentors are – H&M Divided, Zara Kida, Zara Women, Target, the brand
that I have worked for is H&M Divided.
 Brand Aesthetics : About H&M
 Merchandise Mix
Shahi Exports Pvt. Ltd., has well equipped setup of machineries and expertise to handle large
orders for almost all type of commercial garments but is excelled in making the upper
garments. The product ranges from a simple crew neck t-shirt to a hooded jacket,
sportswear, sleepwear, etc. It covers men's & boy's shirts, casual men's shirts, formals, ladies
& girls dress. All types of embellishments, dyes and wash techniques are used in all the four
categories
 Target Consumer Profile
Shahi Exports Pvt. Ltd, has customers who are the leading shopping chains, with head
officers at Europe and USA, where as their retails outlets are spread over the world. The
uniqueness with versatility and competitive prices are demanding factors. Success of a
business depends entirely on understanding the buyer's needs and satisfying the same fully.
 Infrastructure, plant and machinery, expertise of highly skilled and qualified professionals
and commitment to quality have earned it a high degree of trust to its valuable buyers.

 Sizing chart
 Costing
The first step after receiving the tech pack is to calculate the estimated cost of the product
which includes all embellishment costs (printing, embroidery, dyeing etc.), overheads, pro-t
etc. If the buyer approves the cost of the product then it goes into sampling which is further
approved by the buyers. In case, the buyer does not approve the cost, the merchant
calculates the actual cost of the garment keeping in mind the quantity of order.

Research & Analysis

Market Research
Consumer Research
Trend Research (Primary and secondary sources)
Research Analysis/Key Insights 

Concept and Design Development

Design Process Flowchart
Design Brief
Inspiration Board
Mood board and Keywords
Color board
Silhouette Exploration
Fabric  and Trim Directions
Print Directions
Garment Interpretation
Range Planning
Print/Fabric Exploration and Developments
Technical Sketches/Flat Drawings
Specification Sheets
Sampling/Prototyping
Sample Feedback
Costing of final collection
Line Presentation

Styling/imaging
Photo shoot and Look Book
References
Index
Completion Letter