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Documente Cultură
PROFILE ON PRODUCTION OF
BABIES/CHILDREN GARMENT
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TABLE OF CONTENTS
PAGE
I. SUMMARY 26-3
A. TECHNOLOGY 26-10
B. ENGINEERING 26-11
I. SUMMARY
This profile envisages the establishment of a plant for the production of children’s
garment with a capacity of 100,000 pieces per annum.
The present demand for the proposed product is estimated at 2.23 million pieces
per annum. The demand is expected to reach at 3.3 million pieces
by the year 2017.
The total investment requirement is estimated at about Birr 2.49 million, out of which
Birr 696,600 is required for plant and machinery.
The project is financially viable with an internal rate of return (IRR) of 28 % and a net
present value (NPV) of Birr 2.14 million discounted at %.
These products are produced from woven fabrics of cotton or cotton/polyester blead.
They are produced in different designs and fashions. They consist of jacket/coat and
trouser for boys (and girls) and skirts for girls. These garments are finding wide
application in all parts of the country, particularly in urban towns.
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A. MARKET STUDY
The demand for children's cloth in Ethiopia is met both from local production and
imports. However, local production of children's cloth is undertaken mainly by
individual tailors throughout the country. The existing garment factories that are
concentrated in Addis Ababa and its surroundings produce garments predominantly for
civil adults, police and defense forces and workers uniforms.
Due to the shortage of children's cloth from domestic sources, the country has been
importing a substantial amount of children cloth in the past five years. The historical
supply data of children's cloth originating from import is shown in Table 3.1.
Table 3.1 reveals that Ethiopia imports a substantial quantity of babies/children cloth
every year. On the average about 45 thousand kgs of babies cloth worth near Birr 4
million are annually imported to the country.
Of the various types of babies/children cloth, about 48% is made of synthetic fibers.
Children cloth made of cotton accounts for about 16% of the total quantity imported in
the past seven years. The remaining 36% is babies garments made of wool and other
textiles.
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Table 3.1
IMPORT OF BABIES GARMENTS OF WOOL , COTTON, SYNTHETIC
FIBRES AND OTHER TEXTILES (QUANTITY IN KG, VALUE 000. BIRR)
1 2 3 4 Total
Year
Qty Value Qty Value Qty Value Qty Value Qty Value
2000 6,555 1,258 25,188 950 8,605 247 5,066 197 45,414 2,652
2001 1,765 35 47,755 1,020 11,857 259 70,356 1,256 131,733 2,570
2002 34 3 34,550 777 87,550 2,346 162,141 3,902 284,275 7,028
2003 461 14 14,129 338 113,855 3,506 28,812 849 157,257 4,707
2004 2,278 178 4,942 285 65,824 2,361 28,403 1,026 101,447 3,850
2005 - - 9,284 334 18,748 728 8,641 315 36,673 1,377
2006 88 2 3,336 99 116,917 4,147 10,618 46 130,959 4,294
Total 11,181 1,490 139,184 3,803 423,356 13,594 314,037 7,591 887,758 26,478
Average 1,597 213 19,883 543 60,479 1,942 44,862 1,084 126,822 3,783
Taking the above assumption, i.e. 30% as potential buyers, the present effective demand
for children's cloth in SNNPR is 2.23 million Pcs of children's cloth.
2. Projected Demand
Demand for children cloth is mainly influenced by the number of children as well as
income of the household. Thus, taking a 4% average growth rate for demand of
readymade cloth for children aged 0-14 years, a replacement rate of 1 piece per year and
assuming 30% of the total children to be the main customers of industrially produced
garments, the projected demand is shown in Table 3.2.
Table 3.2
PROJECTED DEMAND FOR CHILDREN'S CLOTH IN SNNPR
(MILLION PCS)
Year Qty
2008 2.32
2009 2.41
2010 2.51
2011 2.61
2012 2.71
2013 2.82
2014 2.93
2015 3.05
2016 3.17
2017 3.30
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As could be observed from Table 3.2., the demand for children cloth in SNNPR will
grow from 2.32 million pieces in year 2008 to 3.30 million pieces by the year 2017;
The price of children's cloth depends on the type of the material used. Cotton fabrics and
synthetic fabrics are assumed to be the main materials to be used by the envisaged
project. Accordingly, an average of Birr 30 per piece is adopted for projection sales
revenue .
The products will find their market outlet through existing ready-made garment retail
shops an d by opening a factory shop at strategic locations.
1. Plant Capacity
According to market study, the demand for children’s cloth will grow to 2.32 million
pieces and 3.5 million pieces by the year 2008 and 2015, respectively. It is , therefore,
envisaged that a plant with an annual capacity of 100,000 pieces of assorted children’s
cloth shall be established. The type of children’s cloth and proposed composition is
presented in Table 3.3. A total of 300 working days per annum and a single shift of eight
hours per day is the basis of capacity determination.
Table 3.3
PRODUCTION CAPACITY
2. Production Programme
The envisaged plant will start operation in a single shift, 8 hours a day, and 300 days a
year. Production can be scheduled to grow to full capacity in three consecutive years,
starting at 75% of installed capacity in the first year, and raising the production to 85% in
the second year. Full capacity production will then be attained in the third year and then
after. Production output can be doubled or tripled by introducing a second or third shift
in the daily production programme depending upon the market demand. Table 3.4 below
depicts the proposed production programme.
Table 3.4
PRODUCTION PROGRAMME
Year 1 2 3
Capacity utilization (%) 75 85 100
Production (pcs) – Assorted 75000 85000 100,000
A. RAW MATERIALS
The raw materials required to produce children’s cloth in the envisaged plant include
fabrics, buttons, zippers, elastic braid and sewing threads. As there is no any textile
factory in SNNPRS that produce these items, the fabrics required can be acquired from
either Kombolcha or Bahir Dar Textile factories.
Other relevant raw materials can also be purchased from Addis Ababa. Table 4.1 below
presents annual requirements and corresponding costs of raw materials at full production
capacity.
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Table 4.1
RAW MATERIALS REQUIREMENT AND COST AT FULL CAPACITY
B. UTILITIES
Utilities required by the plant is comprised of electricity, fuel oil and water. Steam is
required for pressing. Table 4.2 presents annual requirement of utilities and
corresponding cost at full production capacity.
Table 4.2
ANNUAL REQUIREMENT OF UTILITIES AND COST AT FULL
PRODUCTION CAPACITY
A. TECHNOLOGY
1. Process Description
The major unit of operations involved in children garment making consist of the
following.
Production of children’s cloth does not have any direct negative impact in environment.
2. Source of Technology
The machinery and equipment required to manufacture children’s clothe are conventional
and available in different technological levels. The best appropriate technology is the
labour intensive one. Suppliers of labour intensive technologies are available in Europe,
Asia and Far East. For the purpose of this project, a German Company whose address
stated below can be considered.
G. M PFAFF A.G
P.O.BOX 3020
D-67653 Kaiserslauter
Germany
Fax (0631) 17202
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B. ENGINEERING
Machinery and equipment required for the envisaged plant are conventional
tailoring/sewing machinery. The list of equipment, quantity and associated costs are
given in Table 5.1.
As shown in the table, the total cost of machinery and equipment is estimated at Birr
696,645 of which Birr 616,645 is required in foreign currency and the remaining Birr
80,000 is in local currency.
Table 5.1
MACHINERY AND EQUIPMENT REQUIREMENT AND COST
The total area required for plant site is estimated to be 1,500 m2. Of this, the built-up
area of the factory will be 500 m2. Building cost is estimated to be Birr 1,500 per m2, and
the total building cost will, then, be Birr 750,000. The cost of land leasing at rate of Birr
1 per m2, per annum and for a total of 80 years land holding , will be Birr 120,000. Thus,
the total investment cost on land, building and civil works, assuming that the total land
lease cost will be paid in advance is estimated at Birr 870,000.
3. Proposed Location
A. MANPOWER REQUIREMENT
The plant will be able to employ 31 persons. Annual salary requirement, including
employee’s benefit, will be Birr 244,500. The mix of production and administrative
manpower required for the envisaged plant is shown in Table 6.1
B. TRAINING REQUIREMENT
It is proposed that production workers (tailors), designers and maintenance crew shall be
given appropriate on-site training in the design, manufacture, quality control and
operation of children’s cloth, and on maintenance and operation of machinery. Such
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Table 6.1
MANPOWER REQUIREMENT AND LABOR COST
The financial analysis of the children’s garment project is based on the data presented in
the previous chapters and the following assumptions:-
The total investment cost of the project including working capital is estimated at Birr
2.49 million, of which 13 per cent will be required in foreign currency.
The major breakdown of the total initial investment cost is shown in Table 7.1.
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Table 7.1
INITIAL INVESTMENT COST
* N.B Pre-production expenditure includes interest during construction ( Birr 113.45 thousand ) training
(Birr 15 thousand ) and Birr 100 thousand costs of registration, licensing and formation of the company
including legal fees, commissioning expenses, etc.
B. PRODUCTION COST
The annual production cost at full operation capacity is estimated at Birr 2.41
million (see Table 7.2). The material and utility cost accounts for 78 per cent, while
repair and maintenance take 3.02 per cent of the production cost.
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Table 7.2
ANNUAL PRODUCTION COST AT FULL CAPACITY ('000 BIRR)
Items Cost %
Raw Material and Inputs 1,761.60 72.94
Utilities 123.6 5.12
Maintenance and repair 73 3.02
Labour direct 193.5 8.01
Factory overheads 0.00 0.00
Administration Costs 51 2.11
Total Operating Costs 2,202.70 91.20
Depreciation 137.16 5.68
Cost of Finance 75.41 3.12
Total Production Cost 2,415.27 100
C. FINANCIAL EVALUATION
1. Profitability
According to the projected income statement, the project will start generating profit in the
first year of operation. Important ratios such as profit to total sales, net profit to equity
(Return on equity) and net profit plus interest on total investment (return on total
investment) show an increasing trend during the life-time of the project.
The income statement and the other indicators of profitability show that the project is
viable.
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2. Break-even Analysis
The break-even point of the project including cost of finance when it starts to operate at
full capacity ( year ) is estimated by using income statement projection.
BE = Fixed Cost = 61 %
Sales – Variable Cost
The investment cost and income statement projection are used to project the pay-back
period. The project’s initial investment will be fully recovered within 4 years.
Based on the cash flow statement, the calculated IRR of the project is 28 % and the net
present value at 8.5 % discount rate is Birr 2.14 million.
D. ECONOMIC BENEFITS
The project can create employment for 31 persons. In addition to supply of the domestic
needs, the project will generate Birr 1 million in terms of tax revenue. The establishment
of such factory will have a foreign exchange saving effect to the country by substituting
the current imports.