After inspection of the incoming materials for shrinkage, GSM, etc, the fabrics are made ready for cutting according to specified designs. Fabrics are relaxed for 24 hours before cutting. After relaxing, the fabrics are placed in layers for marking according to the designs in which they are to be cut.
After cutting, the bundles of cut fabrics are sent to sewing lines, together with trims, thread, label and other accessories. These are assembled according to bundle and number system for sewing. The sewn garments are sorted and stockpiled according to style, colour, size etc. If printing has to be done on the garments, these are sent for printing and washing before segregation according to style, colour etc.
After fixing buttons and trimming & dust sucking, the garments are put up for initial checking, ironing & final checking processes. Thereafter the garments are tagged & sorted as per customer’s specifications before they get into the cartons. The finished products are placed in cartons for storage at a specified, secured storage zone for final inspection & shipping.
Departments of Merchandising, Sourcing and Planning work together to monitor the total requirement in raw materials, its uninterrupted flow, production planning, etc. Any shortage in supply of raw materials is addressed well ahead of the scheduled time of execution and delivery. Alternatives are put in place to ensure that the orders are executed 100% in quantity and delivered on time.
The CLASSIC FASHION Laundry Unit is a complete wash-care unit for wet and dry elements of wash. The installed capacity of the unit is to stone wash nearly 30,000 Denims/garments per day using enzymes. There is an effluent treatment plant for water recycling as a part of the sustainability effort of the Company. All the needs of washed garments, including tinting, are attended to.
The Printing Unit of the CLASSIC FASHION is equipped with screen printing machines with an installed capacity of printing on 20,000 garments per day. The printing machines can print in 6 colour combinations and there are modern heat transfer machines for making heat-seal prints.
The Embroidery Unit of the CLASSIC FASHION has twenty state-of-the-art embroidery machines, each equipped with 20 heads with a pre-programmed system of sewing. Each head has the capacity to adopt up to eight colour combinations in embroidery work on a single garment. Depending on the style and design of the embroidery work needed, the unit has an installed capacity of doing embroidery work on 50,000 to 60,000 garments per day.
Both the factory premises and the area where the employees are accommodated are kept clean and hygienic day and night. Drinking water and bathroom facilities are arranged within the work area itself and kept always clean with running water and uninterrupted supply of electricity. The infrastructure facilities for accommodation are very modern and easy to be kept clean and hygienic. The employees are made aware of the necessity of personal hygiene as an insurance against the spread of diseases.
Directly under the three Managing Partners, there is one General Manager, one Group Factory Manager, one Group Finance Controller, one Manager IT and one Manager Planning. Under the Group Finance Controller there is one Manager Accounts. Under the joint control of the General Manager, Group Factory Manager and Manager Planning there are Manager Merchandise, Manager Warehouse, Manager Administration, Manager Compliance and 6 Factory Managers, one each for the four Factory Units, one for the Laundry Unit and one for the Printing and Embroidery Units.
There are more than 3500 machines in the cutting, sewing and finishing related work in the four Garment Making Units. In the Laundry Unit there are laundry machines to enzyme stone wash 30,000 Denims/garments per day. In the Printing Unit there are screen printing machines, which include 6 colour combination printing and modern heat transfer printing, sufficient for printing on 20,000 garments per day. In the Embroidery Unit there are Twenty Embroidery Machines, each with 20 heads capable of pre-programmed sewing, enough to embroider 50,000 to 60,000 garments per day.
As technology has become a dominant force of the new era, we take various technological initiatives that will help in increasing the productivity and reducing the overhead costs. Our automated manufacturing system through ERP enables efficient production management. This allows us to track and monitor production at all our manufacturing facilities at every stage, so that any changes or bottlenecks can be detected and quickly resolved.
Our factories are streamlined for mass production with production lines that allow our group the flexibility to execute small or large orders with speed. We are EDI compliant with most of our buyers and have invested in a customized IT package. Annually, we spend a substantial amount on technology upgrades, cutting-edge IT solutions relevant to our business and addition of production capacities. Our IT consultants are Teksalah, a premium IT Company based in Dubai, widely acclaimed for their capability in delivering innovative solutions efficiently and in time.
Quality Management Procedures
A systematic and thorough procedure for quality control and management is strictly adhered to at all stages of the purchasing, production and marketing processes.
The purchased fabric, received at the warehouse, undergoes 100% testing for shrinkage, colour fastness etc. before it is issued for production of garments. Trims and accessories undergo a 10% checking for quality before they are issued for production. Before the start of bulk cutting, the size set and pilot run approvals are completed and a 100% checking is done on markers, cut panels, patterns, etc.
On the production line, a 7-point system with traffic signal is installed to check on in-line quality. Besides, a dedicated Auditor conducts random inspections in-line, mid-line and end-line for checking adherence to specifications and quality standards. 100% garment checking with measurement of the product is done mid-line and end-line. Cut-control system is in place to check the garments before wash and after wash. Washed garments are checked 100 percent for washing defects, shortfalls in specifications etc. before the trimming and checking.
These steps are followed by pre-final checking, ironing and final checking with specifications. At this stage a dedicated Auditor is engaged to conduct random inspections in the finishing area to check the perfection and flawlessness in trimming, ironing, packing, etc. Then a 100% checking for tags, ratio, shade etc. is done.
There is a colour card system to analyze and rate/grade the quality output of each individual operator in each section. According to the rating each operator gets, he is either given training for improving his operational standards or for maintaining his operational standards.
Packed products are also subjected to quality check on a regular basis before shipment and there is a colour card system in place for evaluating and rating the work of each quality control auditor in each section. According to the rating each auditor gets, he is either trained for improving his QC standards or for maintaining his QC standards.