Industry Visit Report of
SAI BABA GARMENTS
BY – Ashish Bhuwania
BFT/17/381
INTRODUCTION TO THE INDUSTRY
• Mr. Murlidhar Adtani
Founder / CEO
A visionary man of simple habits had deep faith in God. Mr. Murlidhar Adtani was the
founder of Saibaba Group of concerns in Mumbai in 1973.
• Mr. Prakash Adtani
Director
Saibaba Garments is venture by Mr. Prakash Adtani. He has been in this Industry
since 40 years. His vision of innovative ideas and efforts has given a new recognition
to his company in the garment industry.
- Production base is situated in Bhiwandi which is equipped with Modern Machinery with
work force of 200 people without child labour to produce 75,000 to 1,00,000 pcs per
month.
- The head office of saibaba industry is situated in lower Parel.
Basic Information
Nature of Business Exporter (all to Germany)
Additional Business Manufacturer
Company CEO Prakash Adtani
Year of Establishment 1973
Statutory Profile
GST No. 27AAEFS4843D1Z9
SAIBABA GARMENTS
The Saibaba groups is a government recognised export house manufacturer and exporter of
garments founded by Mr. Murlidhar Adtani in Mumbai, in 1973. The director of the company
Mr. Prakash Adtani has been in the industry since 40 years and has given a new recognition to
his company in the garment industry.
The company headquarters is located at the following address : 345, Pragati Industrial Estate,
N. M. Joshi Marg, Delisle Road, Mumbai, Maharashtra 400011 while the manufacturing unit is
in Bhiwandi. They manufacture garments for German companies.
LAYOUT
PRODUCTION BASE
Their production base in Bhiwandi (near Mumbai) is equipped with Modern Machinery with work force
of 200 people without child labour to produce 75,000 to 1,00,000 pcs per month. Here, in the
production unit the following manufacturing processes take place in the order given below:
• Sourcing
• Fabric Inspection
• Pattern and Marker Making
• Spreading
• Cutting
• Sorting, Bundling and Ticketing
• Stitching
• Labelling
• Pressing
• Final Inspection, Quality Checking, Folding and Packaging
FABRIC SOURCING
• Cotton is sourced from Mumbai itself.
• Chiffon and Georgette are sourced from Surat.
• Fabric is received in the form of bales from the supplier.
• They can store 2Lakh to 2.5Lakh metres in the area. The running process is separate.
• Once they receive an order, the fabric department will place an order to the fabric supplier.
They fill up a fabric requisition form which is sent to the supplier.
• Supplier will approve the fabric and then bulk processing will take place. They follow all
German standards ,i.e., Eco – Free etc.
FABRIC INSPECTION ROOM
After the fabric is received they follow a fabric checklist, which is:
• Checking of basic fabric quality with GSM
• Bulk colour/print shade to match with the approved shade
• Original print swatch to match with the approved swatch
• Colour fastness (rubbing, washing, water and perspiration)
• Misprint (within tolerance depend on the print and coverage)
• Which of the fabric
• Shrinkage (± upto 3 % tolerance allowed)
• Weaving defects
• Fold marks
• Stain
• Finishing (soft hand feel for all fabrics is buyer's choice)
• Cross staining and print impression (not allowed)
• Centre Selvedge
• Running light/dark
• Bowing
• Slippage in fabric
If the fabric is defected, a cross is put in the place of the defect with a heat proof pen and it is
returned to supplier. The defects left after this step will go away in pressing. There were two people
working in this department.
After it is checked ,on every bundle, they write the width of the fabric. Challan’s are made, bale
numbers, metres of fabric cut and used are all noted down and then entered into the software at the
end of the day. After tallying everything, it is issued to the cutting department.
MARKER MAKING
• Marker making is done with the help of CAD machine.
• They manually make the markers and do not use any software to increase the utilization of
fabric.
• The total time required to make one marker was 1-3 hrs depending on the complexity of the
style.
• The marker length is generally about 4 meters and its efficiency is between 75% - 85% and the
marker way is 10. The marker width was around 52.5 inches. The information written on a
marker was size, date, style name, marker length, marker width, efficiency, sets, and client
name.
SPREADING
• Manual spreading is done.
• A total of 150 plies are laid having height up to 6 metres. A maximum of 500 plies could be
done in one day.
• A white fabric is laid on the top of the plies so that the fabric doesn’t get spoilt and white
paper is kept in between a no. of plies so the fabric doesn’t get spoilt.
CUTTING
• A white sheet is laid on the plies which consists of patterns drawn with the help of CAD
software.
• The fabric is cut along the pattern pieces with the help of straight knife cutter.
• It can cut up to 8-10 inches of fabric.
• Around 1,800 garments are cut every day.
• After cutting, the masters do the checking of notches, darts etc.
SORTING
The cut pieces are sorted size wise and garment wise. After bundling, labels are put on the bundles
which consist of serial number, lay number, number of pieces and size of the garment, and are sent
for stitching.
APPROVAL
• Before manufacturing in bulk, a small number of all the dummy sizes – 38, 44, 48 and is
produced and sent to the buyer for the approval.
• After the approval, the stitching of bulk order is started.
STICHING
We then entered the sewing section. Each tailor has a measurement chart on his table.A semi-group
system is followed in which a tailor can stitch an entire garment, or 2-3 tailors can stitch different
pieces and then combine. All the machines are of JUKI.
They used a number of machines for all the operations that were performed. They are listed below:
• Single needle lock stitch
• Double needle lock stitch
• Button hole
• Snap button
• End Cutter
• Fusing
• Stain Removing
• Flat lock
• Smoking
• Pintuck
• Vaccum Ironing Table
• Overlock
FINISHING
After stitching –
• The loose threads at the ends are cut.
• Stain removal.
• Inspection of faults.
• Garments are put up on the dress form and size is checked at the shoulder level, bust level
and hip level.
• The garments are washed and pressed before final packaging.
PACKAGING
Hand tagging → Poly bagging → Packed in cartons → Barcode → Packaging
The company had a very transparent way of working. All the employees were treated very nicely.
They were provided a very homely environment. The plant had their own targets, both daily and
monthly. Employees were graded according to their work.
