Prepared By:
Samadhan Associates Pvt Ltd
22, Greenwood apartments
Gokhle Marg
Lucknow 226001
1. EXECUTIVE SUMMARY
The proposed Denim Jeans Stitching unit is a project of the Textile Sector,
producing standard five pocket jeans trouser. The unit will cater to the local as well
as export denim market. The jeans produced will be of export, high quality fabric.
Through the use of high-tech equipment and modern techniques the company can
produce jeans of latest trends without compromising on quality. The process flow
includes purchase of raw material, cutting, stitching, washing, finishing, pressing
and packing. Quality control checks will be taken care of through out the process.
Indian denim market is on a high growth path with a rate of growth in the range of 8-12%.
However, the market is dominated by the non-branded players who take away the major
share of the denim market. The branded denim market is estimated to be around $450$500 million , and is dominated by some international labels though the local brands are
also getting prominent.
India has become denim hub in the region in less than a decade and is considered as
one of the leading supplier of quality denim fabric to the world's known brands.
India's denim is second to none. There has been a phenomenal increase in the
production capacity of denim mills in India and at present numerous denim mills are
in operation. The denim industry is contributing substantially towards exports
creating job opportunities and has invested billions in the denim sector. The denim
industry is not only fully catering to the needs of the local apparel industry but is
also catering to the foreign market and earning valuable foreign exchange for the
country.
This particular stitching unit is proposed to have an installed capacity for producing
1000 denim jeans per day. The units initial capacity utilization is kept at 70%,
which eventually goes up to 90% in the fifth year. A Denim Garment Stitching Unit
with an installed capacity to produce 1,000 pieces per day needs an investment
estimated at Rs.141.50 Lacs The project is financed through 50% debt and 50%
equity. Projected IRR and Payback of this project are 71.11%, and 3.71 years
respectively. The legal business status of this project is proposed as Sole
Proprietorship.
2.2.Weaknesses
2.3.Opportunities
2.4.Threats
Cost of doing business may increase as the energy, raw material prices,
wages and mark up rates may rise.
3. PROJECT PROFILE
3.1Opportunity Rationale
During the last decade, the usage of denim garments, especially denim jeans, has
been on a rise in the international as well as the local markets. This has led to a rise
in the demand of denim garments. The competitive edge of India in this field stems
from the ready availability of cotton yarn required to weave denim fabric i.e.
During the past few years, the denim fabric manufacturing capacity has also been
enhanced that has provided the opportunity to industry to strengthen. The export of denim
garments from India has also been on a rise.
3.2.Project Brief
The proposed project presents an investment opportunity in manufacturing of denim
jeans. The project profile has been prepared for a standard five pocket jeans trouser.
The proposed stitching unit will be having the potential for its own manufacturing
and supply for the local market as well as for the export market. However washing
will be outsourced.
3.3Proposed Capacity
The proposed capacity of the unit is 1000 garments per day.
3.4.Total Project Cost
The cost of project has been estimated as Rs.141.50 Lacs including machinery and
office equipment.
Project Investment
Capital Investment
Working Capital
Total Investment
Rs. 5,981,220
Rs. 8,169,111
Rs. 14,150,331
The proposed pre-feasibility is based on the assumption of 50% debt and 50%
equity. However this composition of debt and equity can be changed as per the
requirement of the investor.
The project seems to be viable with the following returns on investment.
Project Returns
Internal rate of return (project)
Net Present Value @ 20%
Payback period based on cash inflows
71.11%
Rs. 165,680,748
3.71 years
3.5Proposed Location
The proposed locations for a garment manufacturing unit will be suitable in a Textile
cluster or textile Park developed by the state Government where necessary
infrastructure facilities are available.
3.6.Key Success Factors
The total commercial viability of this proposed stitching unit depends on the regular
orders for the purchase of the finished product. This requires aggressive marketing
efforts at the entrepreneur's end.
Following are other key points that are important for the successful operation of the
proposed stitching unit.
4. MARKET ANALYSIS
Major concentration of the denim garment stitching industry is in Mumbai
,Ahemdabad,Chennai, Newdelhi,Kolkata etc
The average production capacity of majority of small and medium sized jeans
manufacturing units is about 1,000 jeans per day. However, large size manufacturers
are producing as much as 30,000 jean trousers per day.
4.1.Domestic Market
Almost all the established manufacturers are catering solely to the export market.
Only the B-Class products are sold in the domestic market. The size of the
manufacturers, whose primary market is domestic, is quite small.
4.2.Target Customers
In case of direct exports, the customers are retail chain stores, direct distributors and
wholesalers. The export can either be through buying houses and/or through direct
customers.
recommended that the proposed project should outsource washing. Washing cost per
piece is taken as Rs. 30. The production process flow is given in figure 8-1.
Process Flow Chart for Denim Garments Stitching Unit:
Denim Fabric
Raw Material
Inspection
Pressing
Buttoning/ Riveting
Cutting
Stitching
Threading
____________
Final Inspection/
Packing
|
|
------------------5.1.Raw Material
The proposed business will be using the raw material listed in the Table 8-1.
Table 8-1:
Raw Material
Rate
Raw Material
Fabric (Metre)
Pocket Lining (Metre)
Stitching thread (Metre)
Imported buttons
4.5 YG Zip
Main label
Care and size label
Rewet per unit
Packing cost
200
100
/m
/m
/
10 piece
3 / unit
15 / unit
5 / unit
2 / unit
9 / unit
/
15 piece
5.2.Packing Cost
Packing cost includes one poly bag and one small carton for the packing of each
finished garment. Total cost of packing for one piece is taken as Rs. 15.
Manpower Required
Production Staff
Production Manager
Production Planning Officer
Pattern Master
Cutting Master
Cutting Helper
Final Table inspector
Finishing Supervisor
Rowing Inspector
Machine Operator
Helper (machine operator)
Clippers
Iron Presser
Packing Staff
Store keeper
Total
Number
1
1
1
1
2
2
1
1
40
2
2
1
2
1
58
Salary/Month
50,000
25,000
25,000
15,000
8,500
12,000
15,000
12,000
9,000
7,500
7,500
10,000
7,500
10,000
Annual Salary
600,000
300,000
300,000
180,000
204,000
288,000
180,000
144,000
4,320,000
180,000
180,000
120,000
180,000
120,000
7,296,000
Administration Staff
Chief executive
Finance & Admin. Manager
Accounts officer
Marketing Manager
Merchandiser
Export Officer
Purchase Officer
Technician/Electrician
Security Guards
Total
Number
1
1
2
1
1
1
1
1
2
11
Salary/Month
75,000
50,000
15,000
40,000
25,000
25,000
20,000
15,000
8,500
Annual Salary
900,000
600,000
360,000
480,000
300,000
300,000
240,000
180,000
204,000
3,564,000
Quantity
2
15
3
1
1
2
3
1
1
1
1
1
32
1
Lumpsum
32
138,320
25,000
4,000
138,320
25,000
128,000
291,320
4,183,820
Quantity
9
18
6
13
Machine Table
Lay Table
40
12
Total
Equipment
Computers
Printer
UPS
Networking
Air conditioner
Tele/Fax
Total
Total Cost
98
5,000
10,000
200,000
120,000
534,400
9
1
9
1
4
1
24
25,000
15,000
7,500
25,000
40,000
15,000
225,000
15,000
67,500
25,000
160,000
15,000
507,500
1,041,900
Electricity
Water
Gas
Telephone
Fax
9.PROJECT ECONOMICS
Table : Project Costs
Project Costs
Machinery & equipment
Furniture & fixtures/Equipment
Pre-operating costs
Total Capital Costs
Total (Rs.)
4,183,820
1,041,900
755,500
5,981,220
3,951,360
2,092
1,800,000
261,286
2,154,373
8,169,111
14,150,331
50%
50%
7,075,165
7,075,165
14,150,330
10.FINANCIAL ANALYSIS
10.1. Projected Income Statement
PROJECTED INCOME STATEMENT
Year 1
Sales
Cost of goods sold
Raw Material
Washing Cost
(OUTSOURCED)
Freight Charges
Payroll (Production Staff)
Machine Maintenance
Direct Electricity
Total
Gross Profit
Operating Expenses
Payroll (Admin)
Fixed electricity
Insurance expense
Office Expense
(Stationary,Entertainment,
etc)
Administrative & Factory
Overheads
Other expenses
Amortization (Preoperational Expenses)
Depreciation
Total
Operating Profit
Non-operating Expenses
Financial Charges on
Long-term Loan
Year 2
Year 3
Year 4
Year 5
Year 6
Year 7
Year 8
Year
10
Year 9
107,054,171
125,510,319
148,040,625
173,022,480
201,520,300
221,672,330
243,839,563
268,223,519
295,045,871
324,550,459
79,027,200
88,905,600
99,574,272
111,087,547
129,384,320
142,322,752
156,555,027
172,210,529
189,431,582
208,374,741
6,174,000
6,945,750
7,779,240
8,678,715
9,648,689
10,131,123
10,637,679
11,169,563
11,728,041
12,314,443
790,272
889,056
995,743
1,110,875
1,293,843
1,423,228
1,565,550
1,722,105
1,894,316
2,083,747
7,296,000
8,025,600
8,828,160
9,710,976
10,682,074
11,750,281
12,925,309
14,217,840
15,639,624
17,203,586
209,191
219,651
230,633
242,165
254,273
266,987
280,336
294,353
309,070
324,524
1,641,543
1,805,697
1,986,267
2,184,893
2,403,383
2,643,721
2,908,093
3,198,902
3,518,793
3,870,672
95,138,206
106,791,354
119,394,315
133,015,171
153,666,581
168,538,091
184,871,994
202,813,293
222,521,427
244,171,714
11,915,965
18,718,965
28,646,310
40,007,308
47,853,719
53,134,239
58,967,569
65,410,226
72,524,445
80,378,745
3,564,000
3,920,400
4,312,440
4,743,684
5,218,052
5,739,858
6,313,843
6,945,228
7,639,751
8,403,726
882,000
970,200
1,067,220
1,173,942
1,291,336
1,420,470
1,562,517
1,718,768
1,890,645
2,079,710
261,286
235,157
209,029
182,900
156,772
130,643
104,514
78,386
52,257
26,129
712,800
784,080
862,488
948,737
1,043,610
1,147,972
1,262,769
1,389,046
1,527,950
1,680,745
802,906
972,705
1,188,026
1,440,845
1,745,216
2,000,875
2,299,139
2,647,847
3,056,372
3,535,935
60,000
66,000
72,600
79,860
87,846
96,631
106,294
116,923
128,615
141,477
151,100
151,100
151,100
151,100
151,100
522,572
522,572
522,572
522,572
522,572
522,572
522,572
522,572
522,572
522,572
6,956,664
7,622,214
8,385,475
9,243,640
10,216,505
11,059,020
12,171,648
13,418,770
14,818,162
16,390,293
4,959,301
11,096,751
20,260,835
30,763,669
37,637,214
42,075,219
46,795,920
51,991,457
57,706,282
63,988,452
1,132,026
967,419
776,475
554,979
298,044
Financial Charges on
Short-Term Loan
Building Rentel
Total
Profit Before Tax
Tax
Profit After Tax
1,013,997
678,673
1,800,000
1,980,000
2,178,000
2,395,800
2,635,380
2,898,918
3,188,810
3,507,691
3,858,460
4,244,306
2,932,026
3,961,416
3,633,148
2,950,779
2,933,424
2,898,918
3,188,810
3,507,691
3,858,460
4,244,306
2,027,274
7,135,335
16,627,687
27,812,890
34,703,790
39,176,301
43,607,111
48,483,766
53,847,823
59,744,146
506,819
1,783,834
4,156,922
6,953,222
8,675,948
9,794,075
10,901,778
12,120,941
13,461,956
14,936,037
1,520,456
5,351,501
12,470,765
20,859,667
26,027,843
29,382,226
32,705,333
36,362,824
40,385,867
44,808,110
Const.
Year
Current Assets
Cash
Stocks and Inventory
Receivable
Equipment and spare
part inventory
Pre-paid insurnace
payment
Pre-paid building rent
Total
Gross Fixed Assets
Less: Accumulated
depreciation
Net Fixed Assets
Intangible Assets
Pre-operational
Expenses
Total
Total Assets
Current Liabilities
Running Finance
Accounts payable
Total
Long-term liabilities
Long-term Loan
Total
Equity
Paid-up Capital
Retained Earnings
Total
Total Liabilities And
Equity
Year 1
Year 2
Year 3
Year 4
Year 5
Year 6
Year 7
Year 8
Year
10
Year 9
2,154,373
2,154,373
2,154,373
6,040,009
22,300,710
43,901,477
71,166,496
101,488,037
135,173,827
172,560,094
225,474,392
3,951,360
4,445,280
4,978,714
5,554,377
6,469,216
7,116,138
7,827,751
8,610,526
9,471,579
10,418,737
16,058,126
18,826,548
22,206,094
25,953,372
30,228,045
33,250,850
36,575,934
40,233,528
44,256,881
48,682,569
2,092
2,197
2,306
2,422
2,543
2,670
2,803
2,944
3,091
3,245
3,408
261,286
235,157
209,029
182,900
156,772
130,643
104,514
78,386
52,257
26,129
1,800,000
1,980,000
2,178,000
2,395,800
2,635,380
2,898,918
3,188,810
3,507,691
3,858,460
4,244,306
4,668,736
8,169,111
24,875,132
28,348,969
36,381,602
57,517,993
84,277,891
115,541,224
150,263,518
188,792,742
231,509,392
278,829,105
5,225,720
5,225,720
5,225,720
5,225,720
5,225,720
5,225,720
5,225,720
5,225,720
5,225,720
5,225,720
5,225,720
522,572
1,045,144
1,567,716
2,090,288
2,612,860
3,135,432
3,658,004
4,180,576
4,703,148
5,225,720
5,225,720
4,703,148
4,180,576
3,658,004
3,135,432
2,612,860
2,090,288
1,567,716
1,045,144
522,572
755,500
604,400
453,300
302,200
151,100
755,500
604,400
453,300
302,200
151,100
14,150,331
30,182,680
32,982,845
40,341,806
60,804,525
86,890,751
117,631,512
151,831,234
189,837,886
232,031,964
278,829,105
7,242,833
4,847,668
8,297,856
9,335,088
10,455,299
11,664,192
13,585,354
14,943,889
16,438,278
18,082,106
19,890,316
21,879,348
15,540,689
14,182,756
10,455,299
11,664,192
13,585,354
14,943,889
16,438,278
18,082,106
19,890,316
21,879,348
7,075,165
6,046,370
4,852,967
3,468,620
1,862,777
7,075,165
6,046,370
4,852,967
3,468,620
1,862,777
7,075,165
7,075,165
7,075,165
7,075,165
7,075,165
7,075,165
7,075,165
7,075,165
7,075,165
7,075,165
7,075,165
1,520,456
6,871,957
19,342,722
40,202,389
66,230,232
95,612,458
128,317,791
164,680,615
205,066,482
249,874,592
7,075,165
8,595,621
13,947,122
26,417,887
47,277,555
73,305,397
102,687,623
135,392,956
171,755,780
212,141,647
256,949,757
14,150,331
30,182,680
32,982,845
40,341,806
60,804,525
86,890,751
117,631,512
151,831,234
189,837,886
232,031,964
278,829,105
Rs
`000'
Year 10
44,808,110
0
522,572
26,129
(162)
(4,425,688)
10,418,737
1,989,032
53,338,729
0
4,244,306
(4,668,736)
0
(424,431)
52,914,298
172,560,094
225,474,392
11.KEY ASSUMPTIONS
Machinery Assumptions
Number of Machines Installed
Installed capacity
Initial year capacity utilization
Maximum capacity utilization
Capacity utilization growth rate
Defective garment rate (of total finished garments)
Total Production per day
32
100%
70%
90%
5%
2%
1000
Operating Assumptions
Shifts operational per day
1
Hours operational per shift
8
Days operational per year
300
Economy-Related Assumptions
Electricity growth rate
Wage growth rate
10%
10%
45
30
15
30
5%
10%
Rs. 30
5%
Revenue Assumptions
Defected garment sales price
Sales Price growth rate
Rs. 150
10%
Expense Assumptions
Administrative overhead (% of Sales)
Office expenses (stationery, entertainment etc)
Freight expense
Machine maintenance (per month)
Machine maintenance growth rate
Pre-paid building Rent (months)
Pre-paid insurance (months)
Admin and Factory overhead
Insurance rate (% of net fixed assets)
Spare part inventory
Rent growth rate
Tax rate
1%
20% of admin expense
1% of raw material
5% of machinery cost
5%
12
12
0.75% of revenue
5%
0.05% of machine cost
10%
30.90%
Financial Assumptions
Project life (years)
Debt
Equity
Interest rate on long-term debt
Interest rate on short term debt
Debt tenure (years)
Debt payments per year
Discount rate (weighted avg. cost of capital for NPV)
10
50%
50%
14.50%
14.00%
5
1
20%