Presently running four units across Noida with a total of 800 sewing machines, B K Fashions also known as B K Garments, was founded by R K Rathore 30 years ago who began from being just a sewing machine operator. BK Fashions collectively have a turnover of INR 45 crore (US $ 7.5 million), which is expected to rise to INR 55 crore (US $ 9 million) by the end of this financial year. To achieve the growth in its top-lines, the company will establish its fifth unit in Noida with 500 machines, for catering to existing as well as new buyers. The company is now handled majorly by his two sons Amit Rathore and Manish Rathore. Amit has stepped in the role of CEO and Manish as the Director of the company and they use their father’s experience in attaining excellence in product development and manufacturing operations.
Manufacturing value-added garments for kids and women, the company is currently catering to 35 buyers out of which 90 per cent are based in Europe. The company is now looking at the Australian market as well. With big names such as Isabel Marant featuring in their list of buyers, Amit explains that working with such brands, who have stores across the world adds to their credibility, and hence other new buyers do not hesitate much in working with them.
Currently, 60 per cent of B K Fashions’ production is women’s wear and 40 per cent kids’ wear. It has been observed by the company that kids’ wear is growing at a rate slightly higher than that of women’s wear, with French designers opting for embroidery and embellishments for kids’ garments, to give them an Indian touch.
B K Fashions produces basic women’s wear and kids’ wear for US $ 6 and US $ 4, respectively with the FOBs shooting up to US $ 100 for few designs. Currently, 60 per cent of B K Fashions’ production is women’s wear and 40 per cent kids’ wear. Amit informs that kids’ wear is growing at a rate slightly higher than that of women’s wear, with French designers opting for embroidery and embellishments for kids’ garments to give them an Indian touch. The company has an in-house washing and embroidery facility to control the costs.
The company is also regularly developing new types of fabrics every season at mills in south India as well as in Surat, and offering them to the buyers. With four factories in place, the company runs its factories on assembly lines for orders over 1,000 pieces, and on piece-rate system operators for orders less than 1,000 pieces. Amit explains, that although a piece-rate operator knows how to prepare the whole garment, assembly line has its own advantages, like highly-skilled and low-skilled operators can be mixed together which would help in bringing the costs down; whereas piece-rate system requires all skilled operators, which leads to higher costs. To further optimize the manufacturing process, the company has an engineer at the shop floor with an experience of 30 years in the industry, for developing workaids and attachments, and streamlining the sewing operations.
