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About MAL
Hived off from CIVIL in 1992.
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Approx sales turnover Rs. 45 cr.
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Main products were interlining , zips and
needles.
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Main competitors Tata and Bombay dying.
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Products
Interlinings : 50% turnover & 30%
profit.
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Zips : 30% turnover & 40% profit.
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Needles : 20% turnover & 30%
profit.
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Overall Market
Organized ,
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Tata (35% market)
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Bombay dying (35% market)
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MAL (30% market)
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Market cntd.
Unorganized market ,
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Tata (25% market)
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BD (20% market)
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MAL (10% market)
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Local merchants (45% market)
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Supply Chain
MAL produced 85 lakh meters of 200-meter rolls,
using 22 lakh kilos of yarn annually.
Interlinings- material used as an extra lining between
the ordinary lining and the fabric of a garment(for
shaping the garments, also called skeleton of dress)
Yarn
Fabric
weaving
Processed
Fabric
Bleach or dye
Interlining
s
Powder coating
Activities
1.Yarn bought from 4 merchants in Madurai
2.Yarn quality checked in Madurai warehouse
3.Issued to contract weavers for conversion to grey
fabric (7 converters in Erode, Coimbatore,
Madurai and Ambasamudram)
4.Grey fabric brought to Madurai warehouse for
and quality checked
5.Grey fabrics issued to bleaching houses for
conversion to white/coloured fabric (3 converters
in Erode, Bhavani and Ambasamudram)
Continued
6. White/colored fabric brought to Madurai warehouse
and quality checked.
7.
Fabrics
issued
to
own
mfg
house
(Ambassamudram) for final processing and coating to
produce interlinings. Then quality checked, packed
and sent to Bangalore central warehouse (CW)
8. Interlinings stocked at Bangalore CW and sent to
the 11 depots as per dispatch advice.
9. Interlining dispatched to customers (garment
factories and distributors/ dealers) as per requirement
Location involved in
Supply Chain
Yarn (madurai)
weaving
bleaching
process
1/2
depot
Supply Chain
Material/Process
Cost (Rs/mtr)
Yarn
17.75
Weaving
2.25
Bleaching
3.50
Final processing
7.00
Transportation
0.25
Excise duty
10.00
Selling price
48.00
Dilemma
Inconsistency of input.
Inspection costs.
Losses.
Financing the pipeline.
Inconsistency in input
Yarn
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Quality
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uniformity.
P1
S1
S2
P2
MAL
S3
S4
P3
Weaving
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Fabric
weight &
the grey fabric.
Bleaching
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Whiteness
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uniformity.
Inspection costs
Material
Costs(p/mtr)
Yarn
3.1 p/kg
Fabric
14.0 p
Bleached fabric
20.0 p
Final product
24.0 p
Losses
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Wastage convertors,
Reconciliation efforts between purchase orders
and subsequent receipts.
Efforts taken to assign responsibility for rejects
and reconditioning.
To be continued
Quality of the fabric would be checked, packed and
sent to Madurai.
Interlinings of the fabric would be stocked at
Madurai and sent large volume depots, smaller
volume requirements would be sourced from the
nearest large depot as per requirements.
Thank You