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Industrial Field Survey | |

US Denim produces denim fabric for industrial buyers. It exports approximately 60% of this. Its clients include notable brands such as Levis. The remainder is sold in the local market, its biggest buyer being US Apparel. The production of US Denim is 1.8m meters a month and it sells them for Rs 450m a month, while the output of US apparel is worth $5m a month. Their production facilities are situated at Raiwind Road. An assessment of their production house, with regards to workflow, inventory handling, floor layout, quality, safety and human resource, follows below, preceded by a note on their strategy.
Strategy
US Denim and Apparel believe quality is their chief selling proposition. They achieve this by having a production system that augments this goal. This system depends on having state of the art machinery and nurturing their human resource. They have dedicated departments for quality control. They are constantly innovating and trying to make changes to improve their quality and efficiency. Currently Denim is operating on 150% of its capacity by producing 1.8m meters instead of 1.2m meters a month. Aside from the recession and the competition, their biggest challenge arises from the difficulty to sell under the Made in Pakistan brand. They address this by having foreigners on their payroll who are responsible for marketing their products.
Workflow & inventory levels (shop floor)
In US denim, one huge building houses the entire facility. So situating all the departments at the same place assists the smooth, orderly and systematic flow of work. The various departments are connected by a central passageway, that not only facilitates the movement of people and goods, but also houses the inventory (raw material, work in process, finished goods). The inventory levels were not that high in my opinion. The production process is

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