Ratio Analysis on Spinning Industry Ltd

indite of apex textile labyrinthian Apex Spinning & Knitting mill around control Apex Lingerie Limited Apex material picture mill somewhat Limited Apex Yarn Dyeing Limited Contact persons Zahur Ahmed PhD, Managing film director emailprotected com Shahriar Ahmed, Director Operations emailprotected com Marketing & Merchandizing For create from raw materialwear Ershad Ullah Khan, GM emailprotected com MD. Mushahed Alam, Manager emailprotected com Belal Hossain, Manager emailprotected com , For Lingerie and Underwear Shahnaz Begum Zharna (Ms), AGM emailprotected om Nasima Begum (Ms), AGM emailprotected com Apex Holdings Limited Head office Rupayan Golden Age (5th & sixth Floor) 99 Gulshan Avenue, Dhaka 1212, Bangladesh Telephone 880-2-9883358 Fax +880-2-8810850 or 9861685 WWW. apex create from raw stuff. com apexlingerie. com apextextile patsying. com Factory Mouza Chandora, P. O. Shafipur, District Gazipur Profile of the Textile composite plant of ApexHoldings Introduct ion Apex Textile coordination compound consists of four century% export oriented textile and Gar workforcet manufacturing enterprises to a lower place the management of Apex Holdings Limited (AHL).Over the years the companies under AHL have built an enviable reputation of being a reliable vendor of consistent high tone of voice, on time delivery and compliance with international labor laws & env pressmental standards. Companies under AHL have been supplying textiles to some(prenominal) large sell chains in the European Union and north America for the last 20 years and bang prominent status with them. Our reputation is base on the simple philosophy that consistent high quality, on-time delivery and competitive price be the essence of abundant term relationship in export business. The Textile complex is made up of 1.Apex Spinning & Knitting Mills Limited year of fundamental law 1991 Vertical operation, textile to primps 2 . 2 2 . 3 meg pcs/ month knit-garments 2. Apex Lin gerie Limited year of insane asylum 1999 Vertical operation, Fabric to garments 1. 8 2. 0 million pcs/month bra 3. Apex Textile Printing Mills Limited year of establishment 2006 Vertical operation, Fabric to garments 1. 0 1. 2 million pcs/month knit-garments and 3. 4 to 3. 6 million pcs/month of underclothing (mens & ladies) 4. Apex Yarn Dyeing Limited year of establishment 2003 Cotton, polyester & nylon yarn dyeing as well as fasten and embroidery threadsThe AHL textile complex is located in a 17 acre fully own compound, 35 km from Dhaka international airport on Dhaka-Tangail highway. The different units are housed in separate built spaces consisting of about 100,000 square meters. The complex is render with prime power (15 MW), steam (45 T/hr), Thermo boiler (75 million BTU), Hot water (from waste heat), Compressed air (2500 cuM/hour), Process water interposition (8. 0 million liter/day), and effluent treatment (8. 0 million liters/day). Along with the production facilitie s, the complex has a clinic attended by doctors and nurses, childcare facilities.Both these are for workers at free of cost. In addition, there is a large dining area and a subsidized canteen for the workers. 1. Apex Spinning & Knitting Mills Limited Apex Spinning & Knitting Mills Limited (ASKML) is a fully vertical setup to manufacture high quality Knit-garments for Children, Ladies and Mens, victimization inhouse fabrics. ASKML is equipped to produce a wide range of real colour fabrics and all-over printed fabrics (reactive, disperse, vinegarish and pigments) using a variety of designs provided by the buyer and/or from ASKMLs own design segment.The fabric can be circular knit or warp knit, 100% cotton, polyester, nylon or various blends, with or without elastane, yarn dyed or solid dyed, all from in-house source. The 42 sewing lines are equipped to produce garments starting from the basic Page 2 of Profile of the Textile Complex of ApexHoldings childrens items to ladies / mens hooded sport jackets based on designs and specifications and accessories as required by the buyer. The score production capacity of the ASKML is 2. 2 to 2. million pieces per month, as shown below, with decent flexibility to allow 25-40% supernumerary capacity of both one of the items. Infants Pcs / month Childrens Pcs / month 1,500,000 1,600,000 Ladies Pcs / month 200,000 250,000 400,000 450,000 2. Apex Lingerie Limited Apex Lingerie Limited (ALL) has been setup as a fully vertical operation for the sole purpose of manufacturing high quality brassiere. ALL specializes in brassieres using mostly in house fabrics, narrow fabrics ( elasticizeds) etc.Apex Lingerie Limited produces a wide range of styles and designs using a variety of fabrics, lace and accessories based on customers requirement. The plant is fully equipped to produce high quality molded and non-molded bra, with or without pad, with or without under-wire and bra with traditional seams. The total production capac ity of the ALL for the different types of bra is 1. 8 to 2. 0 million pieces of bra per month. The production facility is sufficiently flexible to allow 15-20% additional capacity of any of the items.Sports Bra Pcs/month Girls Bra Pcs/month 500,000- 550,000 Ladies Bra standard Pcs/month 600,000- 650,000 Ladies Bra fashion Pcs/month 300,000- 350,000 400,000- 450,000 3. Apex Textile Printing Mills Limited Apex Textile Printing Mills Limited (ATPML) is a fully vertical setup to manufacture high quality Knit-garments and twain ladies & mens underwear using in-house fabrics. High quality knit-garments for babe and children are manufactured in one floor. In the separate two floors mens and ladies underwear and others intimate apparels are made.Both the sewing floors use in-house fabrics and components manufactured indoors the Apex textile complex. The plant is equipped with facilities to produce garments starting from the infant sleep sack / body suits to ladies / mens hooded sport jac kets, based on designs, fabrics and accessories as required by the buyer. The garments can be from basic to mingled get along & sew, with placement prints, embroidery or twain. Page 3 of Profile of the Textile Complex of ApexHoldings The production capacity of the knitwear instalment of ATPML is about 1. 0 to 1. million pieces per month of knit garments and that of the underwear floors are about 3. 4 to 3. 6 million pieces per month. The two tables below shows the capacities of the 3 floors in ATPML. The capacities of different types of knit-garment, with sufficient flexibility to allow 25-40% additional capacity of any one of the items. Infants Pcs / month Childrens Pcs / month 400,000 450,000 Ladies apparel Pcs / month 300,000 350,000 300,000 400,000 The table below shows the sewing capacities of underwear in ATPML. Childrens underwear Pcs / month 600,000 700,000Ladies underwear Pcs / month 1,200,000 1,250,000 Mans underwear Pcs / month 1,600,000 1,650,000 Facilities wit hin Apex Textile complex Apex textile complex is the combination of these 3 vertical operations, from fabrics to garment factories along with Apex Yarn Dyeing Mills limited. Most of the fabrics and other materials for the garments are produced within the Textile complex. Items like lace, under-wires, ring-slide and some special components are imported. Hangers, poly-bags, printed individual boxes, woven labels etc are locally available. 1. Garment-makingEach of the three garments factories ASKML (knitwear), ALL (Bra) & ATPML (underwear & knitwear) have separate and terminate set-ups for garment manufacturing, starting from design- ingest- intention to garment close. 1. a. Sample, Pattern and design section The section in each of the garment manufacturing units is equipped with CAD (Lectra and/or Garber) systems and between 60 to 80 sewing machines to produce samples according to buyers specifications and /or Apexs own designs (see page XX). every samples are fitted on tolerat e fitting-forms and on live models before sending to the buyers.From digitized patterns, all production markers are produced with optimum efficiency. Page 4 of Profile of the Textile Complex of ApexHoldings Sections of sample, pattern & design discussion section 1. b. Cutting department The cutting department for each of the sewing floors is equipped with fabric recapitulation, 8 to 12 cutting tables, straight knife, ringing knife and stripes fabric pilling or lace pilling setups. The capacities of each cutting departments are carefully matched with the respective sewing capacities, between 60,000 to 100,000 pieces each day. All cut pieces are checked and are prepared into bundles of 20 to 40 pieces.The bundle baskets are sent to the sewing section. Before cutting 100% of the fabrics are inspected and position for sufficient time on cutting tables for relaxation. Sections of the cutting floor Page 5 of Profile of the Textile Complex of ApexHoldings 1. c. sewing department All t he sewing floors are equipped with modern apparel machineries and attachments. The mechanical department is fully equipped with specialized attachment making within facilities. The lines are move out in a manner to allow 100% inspection of the garments during production. Sewing floor 1. d.Finishing department Completed garments in size lots are cleaned of loose threads, dust etc in vacuum suction device, as required. Subsequently, the garments are transferred into an enclosed humidity controlled (air conditioned) room, where, for the Bra and underwear, the garments are inspected and for the knitwears, the garments are finished with steam iron on vacuum tables. After putting all packaging accessories each piece is checked with needle detector before packing for shipment. For all orders, intimate AQL is determined before buyers inspection. Page 6 of Profile of the Textile Complex of ApexHoldingsSections of the finishing floor Another section of the finishing floor 1. e. Molding & La minating Apex Lingerie Limited mainly uses the molding & laminating facility. This section is equipped with foam molding, elastic fabric molding, placed fabric molding, die-cutting (for both foam & fabric) and fabric-fabric, foam-fabric, fiber fill-fabric Laminating machinery. Foam molding depicted object 52,000 pairs/day and fabric molding capacity 70,000 pairs/day. Foam & fabric molding section 1. f. Hook & nerve centre tape making Apex Lingerie Limited mainly uses the hook & eye tape making facility.This section is equipped with fully computerized machinery to Page 7 of Profile of the Textile Complex of ApexHoldings produce both hook tape and eye tapes of up to 4 rows. The Hook & eye capacity is about 80,000 pieces/day. Hook & eye making setup 2. Fabrics A large variety of wide fabrics (circular knit & warp knit), using a wide range of fibers, 100% cotton, polyester, nylon, various blends, micro-fibers with or without spandex and yarn dyed or solid dyed fabrics are produced ex clusively for the garments units within the textile complex. 2. a. Wide FabricsCircular knit fabrics in that location are a total of 145 circular knitting machines, most of the machines are equipped with Spandex attachments and have extra-gauge cylinders. Circular knit fabrics can be solid dyed or yarn dyed, with or without Spandex Total Capacity 3 5,000 Kg / day Single Jersey / Pique Capacity/day16,500 Kg Interlock / drop needle Capacity/day 6,000 Kg Rib / drop needle rib Capacity/day 6,000 Kg Engineering stripe (up to 6 colorizes) Capacity/ day 1,500 Kg 3 thread fleece Capacity/day 5,000 Kg Sections of circular knitting departmentPage 8 of Profile of the Textile Complex of ApexHoldings Warp knit fabrics Solid dyed or yarn dyed, with or without Spandex Tricot Double tricot, Charmeuse, mesh, honeycomb, velour, diamond tulle etc (from rigid to 30 % elastane) Capacity 150,000 meters / month Raschel powernet, satinette, slee knit, one way stretch fabric etc (from 5% to 35 % el astane) Capacity 70,000 meters / month Simplex Various types of Simplex fabrics (up to 35% elastane) Capacity 24,000 meters to 30,000 meters / month Elastane warping, rigid yarn warping and warp knitting sectionsFlat knit fabrics Solid dyed or yarn dyed Collars / cuffs (SHIMA SEIKI) Capacity 6,000 sets / day Fabrics for styling Flat knitting section 2. b. Dyeing & finishing facilities for wide fabrics Dyeing machines are suitable for cotton, spandex cotton, polyamide, polyester, viscose, and various blends Capacity 55,000 Kg / day Page 9 of Profile of the Textile Complex of ApexHoldings 14 sample dyeing machines which can produce 40 different sample fabrics in every day. This department is equipped with both blossom forth width & tubular finishing machinery. Fabric finishing section is equipped with stenter / open-width dryer, tubular-dryer / Tumble dryer / open-width compactor / tubular compactor etc suitable for enzyme finish, silicone finish or any specialized finish (e. g. , Teflon coating, antimicrobial coating etc) Capacity 50,000 Kg / day. In addition to all the options for the chemical finishing, the department has sued- / peach-finishing machines for mechanical finishes. Capacity 5,000 Kg/day. For Fleece fabrics, the finishing section is equipped with raising machines, brushing machine and searing machine. Capacity 10,000 Kg/day.Part of the dyeing department showing a section of the sample dyeing Sections of the dye-finishing Page 10 of Profile of the Textile Complex of ApexHoldings 2. c. Printed Fabrics The stamp section can produce about 50,000 meters/day of printed fabrics, with either reactive, disperse, acid or pigment dyes. The All Over Printing (AOP) section is equipped with One 12 colors Rotary screen printing setup for knit fabrics with a capacity of about 25,000 meters/day. AND One 12 colors Flat-Bed printing setup for knit fabrics with a capacity of about 22,000 meters/day.Loop steamer / polymerizer / after print washing Digita l engraving Computerized design preparation Fully equipped sample & strike off preparation Color kitchen Screen preparation, sample printing Screen preparation, sample printing and 12 color rotary screen printing Page 11 of Profile of the Textile Complex of ApexHoldings 12 color Flat -bed printing Machine 2. d. Narrow fabrics The narrow fabrics section is equipped with all the necessary machinery to produce a wide range of elastic and non-elastic fabrics. Rubber covering (double covering) Capacity 1200 Kg /day Spandex covering (single covering) Capacity 540 Kg / day Needle looms (without jacquard) Capacity 3 50,000 meters / day Needle looms (Jacquard) Capacity 50,000 meters/day Crochet Capacity 60,000 meters / day Narrow fabrics dyeing Capacity 350,000 meters / day Label printing Capacity 200,000 labels / day Narrow fabric weaving, knitting & dyeing Page 12 of Profile of the Textile Complex of ApexHoldings 3. Yarn dyeing Dyed yarn cotton, polyester & nylon Capacity 13 ,000 to 15,000 Kg/day Sewing and embroidery threads Spun polyester, filament polyester / nylon / viscose Capacity 45,000 cones / day . Embroidery Yarn dyeing, winding & spooling Capacity 15,000 pieces/ day Solid Embroidery 9 color machines Applique Embroidery on print Sequence / cording / boring Embroidery section 5. Placement printing Capacity 60,000 to 100,000 pieces / day in up to 6 colors Pigment / Discharge print Puff / Rubber print Page 13 of Profile of the Textile Complex of ApexHoldings Glitter / kettle of fish print Stone attachment Foil printing / metallic shine High density printing Photo print Sections of Placement printing department 6. Pad printing & label printingIn keeping with the need of the market, Apex has setup the facilities to print labels on label tapes as well as printing labels (particularly care labels on bra and underwear) on the body of the garments, using both pad printing machines or using transfer print labels. 7. process plant Capacity 25,000 pcs garment / day The washing plant is equipped to wash knit garments with various additives, enzymes during wash and also during the drying cycle. Page 14 of Profile of the Textile Complex of ApexHoldings Section of the garment washing plant 8. Packaging & StoreAll garments are fully inspected & packaged before inspection by buyer or buyers agent. A large area is allocated for the proper storage of the boxes before shipment. Packaging area and storage 9. tincture control & Textile testing In addition to the modern machinery & equipments, Apex has constantly worked with a wide range of technical experts from Japan, Philippines, Hong Kong and Sri Lanka to improve the working and quality control procedure. Sewing technicians work constantly with the operators and supervisor to upgrade the quality standards and optimize efficiency. QA department personnel conducts inspection of fabric, cutting, molding, bundle preparation and 100% garment quality inspection and recording at all stages of production. Fabric weight (density), yarn count & composition Spectral color matching Color focal ratio to wash, Rub, light etc Shrinkage and other dimensional stability Extension and Modulus etc Page 15 of Profile of the Textile Complex of ApexHoldings Section of laboratory, Spectral equipment and OEKO-TEX enfranchisement In addition, regular testing of yarn, fabrics etc are conducted at our wellequipped lab, accredited by H&M. 0. Product Development and Fashion Design Department For the last several years, Apexs product development team has been working with various buyers to develop new fabrics, prints, narrow fabrics, embellishments etc to create new fashion garments for the export market. base on this experience, in 2010 Apex setup a new independent department for this purpose, staffed by Textile engineers, fashion designers and a complete sample sewing section. The textile engineers in conjunction with the R&D and fabrics departments develop new fabrics, ela stics, prints and other embellishments.Fashion designers use these to develop fashion products for the various export market. This has proven to be very useful to the buyers from USA and Europe and many of them are routinely using this facility. 11. Conformity with International Labour & Environmental Standards Our operations are conducted with sentiency for environmental safeguard and we deem it a s our obligation to prevent pollution by complying with relevant environmental legislations. Apex is one of the countrys very first textiles knit composite industries to have its own Effluent Treatment Plant (ETP) with a daily capacity of 8 million liters/day.Apex Textile complex fully treats all manufactory effluent before releasing into the environment. All the factories within the complex are fully compliant with and or qualified by WRAP certified OEKO-TEX Standard 100 OE (Organic Exchange Certificate) GSV / CTPAT approved Fare Trade ISO 9000 2001 SEDEX Code of Conduct requir ed by major retail stores of the world, e. g. , H&M, Maidenform, Hanes Brands Inc, Vanity Fair, JC Penney, Target, Lindex, Sear-Kmart, Fruit of the loom, Walmart, The Children Place etcWe follow ethical employment practices and adhere to applicable state, National and International laws on labor employment. We provide a clean, safe and healthy environment, adopt fair labor practices, reward them with wages without any discrimination and we do not interfere in their freedom of draw and personal Page 16 of Profile of the Textile Complex of ApexHoldings freedom. In addition, we have the Child care center accommodate with 90 children providing food, nursing etc. 12. Buyers of Apex Textile Complex Our buyers of Knitwear are H&M, Zara, The Morrison, Oshkosh/Caters, Sainsbury, V a n i t y F a i r .Children Place, Ostin, Buyers of Bra are Maidenform, H&M, George UK, Vanity Fair, Matalan, Hunkemoller, Charlott, Sears, Next, JC Penney, Kohls, Target, Lindex, Kappahl . Buyers of Underwear are H&M, George UK, Lindex, Kappahl, DB Apparels, Hema, Next, Pi erre Cardin , 2xist. 13. Delivery time and other mercantile issues Typically an order can be made ready for shipment in 30-90 days depending on approvals of the buyer. Prior to the confirmation of an order, order details and buyers desired delivery dates are sent to the PPIC (Production Planning and Inventory Control) department.Upon receiving the export Letter of Credit or Contract, Apexs merchandizing and commercial department issues purchase orders for the required raw materials. After supplier confirmation of shipment date(s), PPIC department confirms production plans. The production management team, PPIC department, and QAD coordinate the production and the commercial department oversees the export and documentation. 14. How to execute a new order To start business with any of the factories of Apex Textile Complex, you or your representative can visit our factory to see our production facilities, products and co mpliance issues, or have the factory audited.In addition, you can send us any of the following along with the sizes & colors you want and marker date(s) for the shipment(s). A sample of the item(s) you want. OR A sketch of the item(s) you want with complete measurement chart. OR You can ask us to send you samples from our own collections Our merchandizing department will give you our costing(s) and send counter sample(s) as soon as possible with and options of shipment dates. Page 17 of