Year Closing- 2018 &

launching- 2019 meeting

with
KAL-Decathlon
 Fabric Production Status- 2017 vs 2018 (Month wise)
Month 2017 2018
Fabric Production Status- 2017 vs 2018
January 119762 229083
300000

268227
February 149876 199331

March 195688 179048

230616
229083
250000

Production in kg

216475
April 230616 154453

199331

195688

195005
May 268227 151347

179048
200000

172858

169964
164286

157854
154453

152660
June 123516 77296

151347
149876

144554
150000
July 152660 89312

123516
119762

104535
August 172858 56832

89312
100000

77296
September 59235 104535

59235
56832
October 164286 169964
50000

November 157854 144554

December 216475 195005 0

January February March April May June July August September October November December

Grand Total 2011053 1750760 Month

Less business% in 2018 12.9% 2017 2018

 Iman wise Production Quantity- 2018
Component Name Iman Quantity (Kg) Component Name Iman Quantity (Kg)

Alvin 108551 21418 Barcelona 302728 1225

Barcelona 106787 95745 Barcelona 303629 186
Barcelona 109014 85 Barcelona 303661 461
Barcelona 109026 26148 Boston 74899 95534
Barcelona 122419 110087 Boston 115938 21494
Barcelona 122446 52895 Boston 125425 62877
Barcelona 127833 5321 Boston 125425 1040
Barcelona 127842 71 Boston 74899 2200
Barcelona 304190 2067 Carmen Bio 114883 6760
Barcelona 122419 451 Chicago 105839 104636
Barcelona 122419 953 Chicago 108814 29884
Barcelona 122446 2357 Lagos 125940 96247
Barcelona 127833 408 Powell 110321 29603
Barcelona 303728 31150 Sportee 55253 733273
Barcelona 303661 8575 Sportee 128150 17935
Barcelona 303627 34869 Tulear 51972 351
Barcelona 303732 2942 Tulear 111176 4330
Barcelona 303705 8605 Winston 125553 1956
Barcelona 303060 135436 Total 1750760
Barcelona 303628 1185
 Iman wise Production Quantity- 2018
Iman wise Production quantity- 2018
Production quantity (Kg)

800000

733273

700000

600000

500000

400000

300000

200000

135436
110087 104636
95745 95534 96247
100000
62877
52895
26148 31150 34869 29884 29603
21418 21494 17935
85 5321 71 2067 451 953 2357 408 8575 2942 8605 1185 1225 186 461 1040 2200 6760 351 4330 1956
0

Component name & Iman

 Top 5 Fabric in 2018
Component Name Quantity (Kg)
Top 5 Fabric in 2018
Sportee 751208 800000
751208

Production quantity (Kg)

Barcelona 521222 700000

Boston 183145
600000

Chicago 134520 521222

500000

Lagos 96247
400000

300000

200000 183145

134520
96247
100000

0
Sportee Barcelona Boston Chicago Lagos

Component Name
Fabric Inspection Summary Report- 2018
Total fabric inspection= 1750760 Kg.
Total roll= 62084.

1749709.5 Kg-
PASS 99.94%
Pass rolls- 62047

1050.5 Kg- 0.06%

FAIL
Fail rolls- 37
 Fabric Inspection Summary Report- 2017 vs 2018
Pass/Fail 2017 2018 Fabric Inspection Summary Report- 2017 vs 2018
120.00%

Pass 99.92% 99.94%

100.00%

Fail 0.08% 0.06%

80.00%

60.00%

40.00%

20.00%

0.00%
2017 2018

Pass Fail
Top three faults found at fabric Inspection- 2018

Hole-
Hole- 62%

Top three
Dirty
Dirty Spot-
Spot- 27%
27%
fabric faults

Yarn
Yarn Conta.-
Conta.- 5%
5%
 Weekly Blocking Rate of Fabric Inspection- 2018
Week BR%'18 Week BR%'18
W 01 0.00% W28 0.00%
W 02 0.00% W29 0.00%
W 03 0.00% W30 0.00%
W 04 0.00% W31 0.00%
W 05 0.00% W32 0.00%
W 06 0.11% W33 0.00%
W 07 0.00% W34 0.00%
W 08 0.00% W35 Eid Holiday 
W 09 0.09% W36 0.00%
W 10 0.09% W37 0.00%
W 11 0.12% W38 0.00%
W 12 0.00% W39 0.00%
W 13 0.19% W40 0.00%
W 14 0.07% W41 0.00%
W 15 0.15% W42 0.00%
W 16 0.22% W43 0.00%
W 17 0.18% W44 0.00%
W 18 0.25% W45 0.00%
W 19 0.31% W46 0.00%
W 20 0.29% W47 0.00%
W 21 0.35% W48 0.06%
W22 0.21% W49 0.00%
W23 0.10% W50 0.00%
W24 0.04% W51 0.00%
W25  Eid Holiday W52 0.00%
W26 0.00% W53 0.00%
W27 0.00%
 Weekly Blocking Rate of Fabric inspection- 2018
Weekly Blocking Rate of Fabric Inspection- 2018
0.40%

0.35%

0.30%

0.25%

0.20%

0.15%

0.10%

0.05%

0.00%
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 eek 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53
W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W

Target Blocking Rate <5% (Achievement 0.06%)

 Fabric Test summary Report- 2018

 Total Batch Tested: 3436

 Pass Batch: 3350
 Fail Batch: 86

Pass-97.5% Fail-2.5%
 Fabric Test summary- 2017 vs 2018

Fabric Test summary- 2017 vs 2018

Pass/Fail 2017 2018
120.00%

100.00% 97.62% 97.50%

Pass 97.62% 97.5%

80.00%

60.00%
Fail 2.38% 2.5%

40.00%

20.00%

2.38% 2.50%
0.00%
2017 2018

Pass Fail
 Weekly Blocking Rate of Fabric Test Report- 2018
Weekly Blocking Rate of Fabric Test Report- 2018
6.00%

5.00%

4.00%

3.00%

2.00%

1.00%

0.00%
W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53

BR%'18

Target Blocking Rate <5% (Achievement 2.5%)

 Weekly Blocking Rate of Fabric Test- 2017 vs 2018
Week BR%'17 BR%'18 Week BR%'17 BR%'18
W 01 1.50% 3.20% W 28 1.50% 2.61%
W 02 1.40% 2.00% W 29 0.80% 0.00%
W 03 1.50% 1.44% W 30 1.30% 0.00%
W 04 1.30% 1.70% W 31 1.40% 1.75%
W 05 1.20% 1.34% W 32 1.90% 1.80%
W 06 2.90% 1.42% W 33 1.90% 2.44%
W 07 2.00% 1.63% W 34 1.50% 2.50%
W 08 1.70% 1.78% W 35 2.60%  Eid Holiday
W 09 1.70% 2.47% W 36  Eid Holiday 1.68%
W 10 0.80% 2.58% W 37 2.90% 3.62%
W 11 1.10% 2.78% W 38 3.40% 2.48%
W 12 1.00% 3.19% W 39 3.90% 2.37%
W 13 1.40% 2.48% W 40 1.80% 1.65%
W 14 2.60% 3.83% W 41 0.80% 1.09%
W 15 2.90% 3.30% W 42 1.20% 4.37%
W 16 4.20% 3.10% W 43 2.90% 4.46%
W 17 4.40% 2.50% W 44 3.00% 5.63%
W 18 3.70% 2.30% W 45 3.80% 5.58%
W 19 3.50% 2.00% W 46 3.50% 2.99%
W 20 2.10% 0.80% W 47 2.90% 2.64%
W 21 1.50% 1.80% W 48 3.80% 1.76%
W 22 1.00% 3.96% W 49 3.80% 1.88%
W 23 0.50% 2.82% W 50 5.40% 1.28%
W 24 1.20% 4.72% W 51 5.30% 1.09%
W 25 1.30%  Eid Holiday W 52 3.80% 1.12%
W 26 Eid Holiday  3.08% W 53 0.00% 2.04%
W 27 1.20% 2.60%
 Weekly Blocking Rate of Fabric Test- 2017 vs 2018
Weekly Blocking Rate of Fabric Test- 2017 vs 2018
6.00%

5.00%

4.00%

3.00%

2.00%

1.00%

0.00%
W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53

BR%'17 BR%'18
 ETP Performance- 2018
Test Results ( ETP Out-let Water)
Department of
Test Parameter Environment (DoE) Decathlon Requirement
Requirement
Jan'18 Feb'18 Mar'18 Apr'18 May'18 Jun'18 Jul'18 Aug'18 Sep'18 Oct'18 Nov'18 Dec'18

COD (mg/L) ≤200 ≤160 83 74 78 82 76 80 73 83 85 95 87 90

BOD (mg/L) ≤50 ≤30 25 24 26 29 18 16 28 15 20 25 27 24

DO (mg/L) 4.5-8.0 For ref. only 6.11 6.23 7.31 6.34 6.38 6.15 6.77 6.10 6.12 6.14 6.19 6.18

pH 6.0-9.0 6.0-9.0 7.49 7.61 7.63 7.59 7.56 7.58 7.41 7.75 7.78 7.51 7.71 7.65

TSS (mg/L) / ≤50 13 10 12 15 20 14 16 18 17 13 9 11

TDS (mg/L) <2100 / 1488 1613 1389 1459 1509 1612 1550 1510 1300 1400 1360 1550
 Carbon Emission Status
Engine Jacket Water Heat Recovery System

Objective: To reduce energy cost and CO₂.

Total investment: 68385 USD.
Pay back period: 06 Months.
Total natural gas save: 10,71,228 m³ (Per Year).
Total cost save: 1,45,457 USD (Per Year).
Total steam save: 25,655 Ton (Per Year).
Total CO₂ reduce: 2,305 Ton (Per Year).
Total capacity: 39.75 m³/h
 Success
 Lab validation.
HRP assessment done successfully.
BARCELONA shrinkage issue- High alert deactivated.
Deactivation of Pilling assessment has removed.
Fabric inspection pass percentage is 99.94% in 2018.
Consistent inspection blocking rate throughout the year.
Consistent test blocking rate throughout the year.
On time fabrics delivery.
Standup meeting started & continuing successfully.
PY training & assessment done.
 Success
Faster component Homologation, so more scope of business.
CO₂ project launched successfully.
Process routes & parameters visualization.
We are heading to start Fabric sell business.
Showroom procedure done successfully (Submitted Hangers & Design Cards).
Strong Business relationship. As a result-
 Validated Lab. We are conducting test SGS-1 out of KAL-16.
 We have the autonomy for approving all shade card from our end. Decathlon is approving Lab Dip, 1 st
dye lot & Implantation Shade cards.
 Continuous improvement of quality.
 Challenges

Fabric Sell.
Order volume fluctuation.
 Extreme cost pressure.
 Yarn Sourcing switching (Regular to BCI).
 Shorter lead time.
In-house fabrics consumption less due to more
Imported fabrics.
 Difficulties

Costing of Moisture Management test @SGS.

PLF issue has not been solved yet.
Confirm order & Forecast ratio.
 Expectations

Less imported or outside fabric & maximum uses of

inhouse fabric.
Less volume fluctuation.
Less forecast quantity.
Increase business.
Reasonable price.
Thank You