INDUSTRY PROFILE #4
MEN'S
WASH AND WEAR PANTS
Prepared By
Edward Hochberg
Reviewed By
George J. Coury
Robert W. Rugenstein
VITA
Published By
VOLUNTEERS IN TECHNICAL ASSISTANCE
1600 Wilson Boulevard, Suite 500, Arlington, Virginia 22209
USA
Telephone: (703) 276-1800, Fax: (703)
243-1865
Telex: 440192 VITAUI, Cable: VITAINC
Internet:
vita@gmuvax.gmu.edu, Bitnet: vita@gmuvax
Men's Wash and Wear Pants
ISBN: 0-86619-291-3
[C]1987, Volunteers in Technical Assistance
INDUSTRY PROFILES
Introduction
This Industry Profile is one of a series briefly describing
small or medium-sized industries. The
Profiles provide basic information for starting
manufacturing plants in developing nations.
Specifically, they provide general plant descriptions,
financial, and technical factors for their
operation, and sources of information and expertise. The
series is intended to be useful in
determining whether the industries described warrant further
inquiry either to rule out or to
decide upon investment. The underlying assumption of these
Profiles is that the individual
making use of them already has some knowledge and experience
in industrial development.
Dollar values are listed only for machinery and equipment
costs, and are primarily based on
equipment in the United States. The price does not include
shipping costs or import-export taxes,
which must be considered and will vary greatly from country
to country. No other investment
costs are included (such as land value, building rental,
labor, etc.) as those prices also vary.
These items are mentioned to provide the investor with a
general checklist of considerations for
setting up a business.
IMPORTANT
These profiles should not be substituted for feasibility
studies. Before an investment is made in
a plant, a feasibility study should be conducted. This may
require skilled economic and
engineering expertise. The following illustrates the range
of questions to which answers must
be obtained:
*
What is the extent of the present demand
for the product, and how is it now being
satisfied?
*
Will the estimated price and quality of
the product make it competitive?
*
What is the marketing and distribution
plan and to whom will the product be
sold?
*
How will the plant be financed?
*
Has a realistic time schedule for
construction, equipment, delivery, obtaining
materials
and supplies, training of personnel, and the start-up time for the plant
been
developed?
*
How are needed materials and supplies to
be procured and machinery and
equipment
to be maintained and repaired?
*
Are trained personnel available?
*
Do adequate transportation, storage,
power, communication, fuel, water, and
other
facilities exist?
*
What management controls for design,
production, quality control, and other
factors
have been included?
*
Will the industry complement or interfere
with development plans for the area?
*
What social, cultural, environmental, and
technological considerations must be
addressed
regarding manufacture and use of this product?
Fully documented information responding to these and many
other questions should be
determined before proceeding with implementation of an
industrial project.
Equipment Suppliers, Engineering Companies
The services of professional engineers are desirable in the
design of industrial plants even though
the proposed plant may be small. A correct design is one
that provides the greatest economy in
the investment of funds and establishes the basis of
operation that will be most profitable in the
beginning and will also be capable of expansion without
expensive alteration.
Professional engineers who specialize in industrial design can
be found be referring to the
published cards in various engineering magazines. They may
also be reached through their
national organizations.
Manufacturers of industrial equipment employ engineers
familiar with the design and installation
of their specialized products. These manufacturers are
usually willing to give prospective
customers the benefit of technical advice by those engineers
in determining the suitability of their
equipment in any proposed project.
VITA
Volunteers in Technical Assistance (VITA) is a private,
non-profit, volunteer organization
engaged in international development. Through its varied
activities and services, VITA fosters
self-sufficiency by promoting increased economic
productivity. Supported by a volunteer roster
of over 5,000 experts in a wide variety of fields, VITA is
able to provide high quality technical
information to requesters. This information is increasingly
conveyed through low-cost advanced
communication technologies, including terrestrial packet
radio and low-earth-orbiting satellite.
VITA also implements both long- and short-term projects to
promote enterprise development and
transfer technology.
MEN'S WASH AND WEAR PANTS
PREPARED By: Edward
Hochberg
REVIEWED By: Robert
W. Rugenstein
George
J. Coury
PRODUCT DESCRIPTION
1. The Product
Men's pants are made from wash and wear material. They come
in
waist sizes ranging from 28 to 44, and lengths from 30 to 36
inches. Shorts,
boys' pants, uniform trousers, and work pants
other than jeans can also be made from the same material.
2. The Facility
This Profile describes one plant operating with one shift
and
producing 15,000 dozens pairs of pants a year, and another
that
produces 22,000 dozens a year.
It is important for a small factory to be able to produce
varied
styles. Therefore,
it is imperative to have a designer/pattern-maker
available to quickly produce properly fitted items as may
be requested by the customer.
GENERAL EVALUATION
Wash and wear pants are readily marketable because they are
low-priced compared with slacks.
The investment needed to
establish this plant is small when compared with the number
of
people employed. The gross profit estimate is favorable.
1. Outlook
A.
Economic
Depends on
the conditions in country.
B.
Technical
Good
reconditioned sewing machines can perform just as
well as some of the items listed on page 4. They may cost
half
the price of new machines.
2. Manufacturing
Equipment Flexibility
The machinery and equipment used to produce men's pants are
similar to the kind used in the apparel industry to
manufacture
other types of clothing. Therefore, it is possible and
strongly
recommended that other kinds of clothing or other fabric
items be
made at this plant. In other words, it should not be
confined to
manufacturing a single item.
3. Knowledge Base
A good business plan is necessary. A two to three-year
projection
should be prepared and caution taken against overextension.
Other considerations of management should include:
a) Business
experience
b) Knowledge of
field
c) Sources of
capital
d) Knowledge of
market
e) Knowledge of
procurement of material and equipment
f) Capability to
find government support
4. Quality Control
Quality control is very important, and specifications vary
from
company to company and from garment to garment. For example,
an
entire order may be rejected for as little an error as the
number
of stitches per inch or the tension of the thread.
5. Constraints and
Limitations
There may be a shortage of skilled designers,
pattern-makers,
cutters, and mechanics.
--No special
transportation requirements, but good highways
would be
helpful.
--Manager and supervisors should be fully
experienced.
--Some operators
will be operating more than one machine.
--After break-in
period, production workers should go on piece
work rates.
--A reliable
electric power system is needed.
MARKET ASPECTS
1. Users
Men and
teenagers.
2. Suppliers
In most urban centers there are sales representatives of
equipment
manufacturers and jobbers of fabrics.
It may be too
expensive to go to the United States or other western
nations to
look for design, fabrics, and machines. Hong Kong and Tokyo
are
also good sources for these items.
3. Sales Channels
and Methods
Sales will be made directly to large stores and to
wholesalers
for resale to small retailers. The domestic rate of
consumption
of men's wash and wear pants will depend primarily upon wage
levels and clothing habits of the population. The product
should
be well packaged in cardboard boxes that can be transported
easily anywhere within the country.
One path to explore is contracting with U.S. garment
manufacturers
to supply a steady source of work for the plant.
Large
investments in plant and equipment for exports should not be
undertaken unless there is a written commitment from the
manufacturer
or contractor who can guarantee an outlet for the garments.
4. Geographic Extent
of Market
Domestic - The product is easy to ship and transport costs
are
normally low in relation to product value. Market may be
nationwide.
Export - Some export sales to neighboring nations not having
such
factories might be possible.
5. Competition
Domestic Market - Very small makers and imports may provide
competition.
Export Market - The plant is relatively small and might have
great difficulty in competing with mass producers or with
exports
from areas where labor is plentiful and cheap.
6. Market Capacity
Under average conditions a population of about a million
would
probably be large enough to support production for a plant
of
this size.
PRODUCTION AND PLANT REQUIREMENTS
Requirements
Annual Output:
15,000 dozen
22,000 dozen
1. Infrastructure,
Utilities Small Plant
Medium Plant
Land
1/2 acre
1/3 acre
Building one
story 6,000 s.f.
10,000
Power connected
load 100 hp
120 hp
Fuel (for steam,
heat)
Water
(processing, sanitation, fire)
Other
2. Major Equipment
& Machinery Small Plant
Medium Plant
Units
Units
Tools &
Machines
cloth
spreader
(1) (1)
cloth
unwinder
(1) (1)
cutting
tables
(2)
(2)
cutting machine
(heavy duty) (3)
(4)
cloth drill
(1)
(1)
buttonhole
machine (2)
(1)
buttonsewer
machine (1)
(1)
safety
stitch
(10) (10)
single
needle
(9) (9)
overlock
(2)
(2)
double needle
flatbead (1)
(1)
double needle
machine for
waistband
& belt loops (3)
(3)
bartack
(1)
(2)
pocket press
(1)
(1)
(1)
Support
Equipment & Parts
furniture &
fixtures
hand trucks
(3)
(3)
20 hp
boiler
(1) (1)
pressing
machine
(1)
(2)
racks
(6)
(10)
chairs &
workbenches (36)
work tables
storage shelves
spare parts
& tools
truck/van
(3)
(1)
work baskets
*TOTAL ESTIMATED COST
of equipment & machinery only
$103,000
$116,000
*Based on $US 1987 prices. The costs provided are estimates
and
are given only to provide a general idea for machinery
costs;
they are not intended to be used as absolute prices. Costs
still
need to be determined on a case by case basis.
3. Materials &
Supplies* Small Plant
Medium Plant
Raw Materials
fabric
360,000 yards
540,000 yards
lining (for waistband &
pockets)
40,000 yards
60,000 yards
thread (12,000
yd. cones) 3,600 cones
5,000 cones
zippers
15,000 dozen
23,000 dozen
buttons
4,000 gross 5,700
gross
hang tags
15,000 dozen
23,000 dozen
labels
15,000 dozen
23,000 dozen
metal
fasteners 15,000
dozen 23,000 dozen
Supplies
lubricants
$ 3,000
$ 4,000
office &
factory supplies
gas, oil &
truck maintenance 2,000
2,000
Packaging
shipping cartons
hangers
4. Labor
Small Plant
Medium Plant
Skilled
designer/pattern
maker 1
1
cutters
2
3
operators
26
36
pressers
4
6
floor help
6
8
Semi-skilled
Unskilled
4
5
Administration
manager
1
1
office
1
1
supervisor
1
2
mechanic/chauffeur
1 1
5.
Distribution/Supply flow
Small Plant Medium
Plant
Amount in/out per
day 60 dozen
80-95 dozen
6. Market
Requirements Small
Plant Medium Plant
Population
1 million
*This includes an approximate amount of materials used over
a
period of a year. It does not mean that a year's supply must
be
stored on the premises.
PROCESS DIAGRAM <see plant layout and work flow>
mwax6.gif (600x600)
REFERENCES
Unless otherwise stated, these addresses are in the United
States.
1. Technical Manuals
& Textbooks
Fashion Institute of Technology 7 Ave. & 27 St.
New York, New York 10001
Library and bookstore with full listing of books on design,
pattern-making, marketing.
Model Garment Factory for Men's Shirts and Trousers.
United
Nations Industrial Development Organization.
December, 1974.
31 pages.
2. Periodicals
Women's Wear Daily & Daily News Record
Fairchild Publications
7 E 12 Street
New York, New York 10003
Bobbin Magazine
Bobbin International
PO Box 1986
1110 Shop Road
Columbia, South Carolina 29202
Apparel Industries Magazine
180 Allen Street
Atlanta, Georgia 30328
Apparel World
366 Park Avenue, South
New York, NY 10016
3. Trade
Associations
American Apparel Manufacturing Association
2500 Wilson Blvd.
Arlington, Virginia 22201
(703) 524-1864
National Knitwear & Sportswear Association
366 Park Ave., South
New York, New York 10016
4. Equipment
Suppliers, Engineering Companies
Hudson Sewing Machine Co.
109 Johnston St.
Newburgh, New York 12550
(dealer in all types of equipment)
Singer Corporation
135 Raritan Center Parkway
Edison, New Jersey 08837
(sewing room equipment, cutting room equipment)
Kurt Salmon Associates
350 Fifth Avenue
New York, New York 10118
(management consultants, consulting services)
5. Directories
Buyers Guide:
A Sourcing Guide for the Apparel Industry
produced by
The Associate Membership Congress
American Apparel Manufacturers Association
2500 Wilson Boulevard
Arlington, Virginia 22201
6. VITA Resources
VITA has a number of documents on file dealing with the
textile
and clothing industry. For example:
Selected Information Resources on Textiles.
Compiled by J.A.
Feulner, National Referral Center, Library of Congress, May,
1980. 17 pp. XII-E-1, P. 1, 022470, 12.
7. VITA Venture
Services
VITA Venture Services, a subsidiary of VITA, provides
commercial
services for industrial development.
This fee-for-service
includes technology and financial information, technical
assistance,
marketing, and joint ventures.
For further information,
contact, VITA.
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