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    Uttam Das943441729106

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    FAMILY CARE
    The document describes the manufacturing process of handloom sarees, mekhalas, and dokhnas by Ajay Handloom Unit. [1] Each saree is hand woven over 4-8 days through a process that includes dyeing cotton or silk fabric, drying the fabric, rolling it onto sticks, and weaving using handloom machines. [2] There is high demand for these handloom products throughout India. [3] The manufacturing process, costs of production, expected sales and profits are presented.

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    Uttam Das943441729106

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    FAMILY CARE
    64 views6 pages
    The document describes the manufacturing process of handloom sarees, mekhalas, and dokhnas by Ajay Handloom Unit. [1] Each saree is hand woven over 4-8 days through a process that includes dyeing cotton or silk fabric, drying the fabric, rolling it onto sticks, and weaving using handloom machines. [2] There is high demand for these handloom products throughout India. [3] The manufacturing process, costs of production, expected sales and profits are presented.

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    The document describes the manufacturing process of handloom sarees, mekhalas, and dokhnas by Ajay Handloom Unit. [1] Each saree is hand woven over 4-8 days through a process that includes dyeing cotton or silk fabric, drying the fabric, rolling it onto sticks, and weaving using handloom machines. [2] There is high demand for these handloom products throughout India. [3] The manufacturing process, costs of production, expected sales and profits are presented.

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    64 views6 pages

    Uttam Das943441729106

    Uploaded by

    FAMILY CARE
    The document describes the manufacturing process of handloom sarees, mekhalas, and dokhnas by Ajay Handloom Unit. [1] Each saree is hand woven over 4-8 days through a process that includes dyeing cotton or silk fabric, drying the fabric, rolling it onto sticks, and weaving using handloom machines. [2] There is high demand for these handloom products throughout India. [3] The manufacturing process, costs of production, expected sales and profits are presented.

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    of 6

    AJAY HANDLOOM UNIT

    SAREES, MEKHLA ,DOKHNA

    1. INTRODUCTION: The plain fabric is used as a raw material in


    manufacturing printed bed sheets,
    sarees, material, furnishings, etc. The finished handloom cloth can
    be
    supplied either bleached or unbleached and in a wide range of colours
    and shades.
    For coloured cloth, the yarn is bleached and dyed before weaving.
    2. MARKET :There is good demand for cotton cloth throughout the
    country. There is shortage felt
    in the supply of cloth in wholesale market according to the dealers.
    The demand for cotton fabric is oin increase for use as sarees,
    dokhna,mekhla, etc The cloth from handlooms is cheaper in price with
    quality finish.
    3. MANUFACTURING PROCESS:
    Each and every thread of the gadwal saree is hand woven. All the process involved in
    weaving a saree is carried out manually, no machine is used in any of the steps. Each weaver
    works from home with all his/her family helping in different steps of the process. Their life
    revolves around weaving. It requires approximately 4-8 days (depending on the variety of
    saree) of continuous efforts from two persons for weaving a saree on a handloom machine.
    The core materials used for manufacturing the saree are Silk/Cotton and Jari. We import
    silk/cotton from Bangalore and gold/silver jari from Surat.

    Silk Cotton White Jari Red Jari


    The major steps involved in manufacturing a saree are described briefly below.
    Step 1: The process starts with dyeing the silk/cotton material. We have specially dedicated
    experts for this process. In short the coloring process includes dipping the material repeatedly
    in the boiled color water. We take the utmost care while dyeing the silk/cotton to make sure
    that the color is uniform throughout the material and it doesn't affect the quality of the
    material. The coloring process is a very crucial step in getting a good saree. The colors are
    applied as per the specifications from our designers and also as per the orders from our
    customers.

    Coloring process
    Step 2: After coloring the silk is dried in shade. Drying the material in sunny can harm the
    material.

    Drying the material


    Step 3: After the silk is dried, it is rolled over small sticks (called kandis locally).
    Step 4: The next step involves the actual weaving process of the saree. Please see the
    handloom machines used for weaving the saree in the below pictures.

    Handlooms
    Gadwal Sarees are traditionally woven in the interlocked-weft technique (called kupadam or
    tippadamu locally) and often with kotakomma (also called kumbam) in the borders and they
    are known as a kotakomma or kumbam saree. The silk border is either tussar or mulberry and
    the body is often of unbleached cotton, although it may also have colored cotton or silk
    checks. Pure silk versions of Gadwal sarees are also available.
    The design required on the saree is initially drafted on a graph paper and then the required
    setup to weave that design is implemented on the handloom machine using the sheet. We
    have experts for implementing these innovative designs on borders, body and pallu. All the

    required setup is made on the handloom machine by our experts before weaving the saree.

    Weavers at work

    4.PRODUCTION CAPACITY PER ANNUM

    Capacity 3000 pic


    Selling Price 30,00,000
    5.PROJECT COST/CAPITAL INVESTMENT

    S.No Description Amount Rs.


    1 Preliminary & Preoperative Expns 5000
    2 Fixed Capital 4,00,000
    3 Working Capital for 3month(s) 5,62,500
    Total Project Cost 9,67,500
    6. MEANS OF FINANCE

    S.No Description %age Amount Rs.


    1 Promoter Contribution 10% 96,750
    2 Subsidy /Soft Loan 25% 2,41,875
    3 Term Loan 65% 6,28,875
    Total 9,67,500
    7. FINANCIAL ASPECTS

    A. FIXED CAPITAL
    i. Land own
    Buildings making ,76,000

    ii. Machinery and Equipment

    S.No Description Qty. Rate Amount Rs.


    1 handlooms 10 30,000 3,00,000
    2 Installation and electrification 1 20,000 20,000
    3 Miscellaneous expenses 1 4,000 4,000
    Total 3,24,000
    TOTAL FIXED CAPITAL (i+ ii.) 76,000+3,24,000=4,00,000

    B. WORKING CAPITAL

    i. Salaries & Wages (per month)


    S.No Description Nos. Sal/mon. Amount Rs.
    1 Supervisor/Entrepreneur 1 10,000 10,000
    2 Skilled Labour 10 9,000 90,000
    3 Semi-skilled Labour 2 3,000 6,000
    4 Unskilled Labour 1 2,000 2,000
    Total 1,08,000
    ii. Raw Material (per month)

    S.No Description Unit Qty. Rate Amount Rs.


    1 Yarn kg 125 600 75,000
    Total 75,000
    iii. Utilities (per month)

    S.No Description Unit Amount Rs.


    1 Power LS 3000
    Total 3000
    iv. Other Expenses (per month)

    S.No Description Amount Rs.


    1 Postage & Stationery Expenses 200
    2 Transportation Expenses 500
    3 Consumeble Stores 500
    4 Miscellaneous Expenses 300
    Total 1500

    v. Total Working Capital (per month)


    S.No Description Amount Rs.
    1 Salaries and Wages 1,08,000
    2 Raw Material 75,000
    3 Utilities 3,000
    4 Other Expenses 1,500
    Total 1,87,500
    8. COST OF PRODUCTION (PER ANNUM)

    S.No Description Amount Rs.


    1 Total Working Capital 22,50,000
    2 Depreciation @15% 60,000
    3 Interest @12% 75,465
    Total 23,85,465
    9. TURNOVER (PER YEAR)

    S.No Description Unit Qty. Rate Rs. Amount Rs.


    1 hamdlooms pic 3,000 1,000 30,00,000
    Total 30,00,000

    10. FIXED COST (PER YEAR)

    S.No Description Amount Rs.


    1 Depreciation 60,000
    2 Interest 75,465
    3 Salaries & Wages @40% 5,18,400
    5 Other Expenses incl. Utilities @40% 21,600
    Total 6,75,465
    11. PROFIT ANALYSIS & RATIOS

    1 Net Profit Rs.6,14,535


    2 Percentage of Profit on Sales 20.48%
    3 Percentage of Return on Investment 63.51%
    4 Break Even Point 52.36%

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