Kurti Manufacturer Interview Notes (Mumbai)
Interview Overview
This set of notes summarizes an interview with Mohammad Ajitam, a kurti (kilts? kurtis) manufacturer based in Mumbai. The interviewer is a student from FBMS B division, and the focus of the discussion is the end-to-end blog topic on a business vendor’s workflow, challenges, and market approach. The conversation centers on moving from outsourcing to in-house production, the steps involved in creating a finished kurti, the customization offerings, fabric choices, seasonal adjustments, and the channels used to sell the products online and offline. A collaborator named Mohammad Shyam is also acknowledged for providing feedback from a young age.
Company Profile and Person
Mohammad Ajitam presents himself as a kurti manufacturer operating out of Mumbai. He describes a career shift from taking job-work for large companies to building an end-to-end manufacturing capability in-house. The motivation behind starting his own line was to control the entire process rather than relying on external producers to complete the whole supply chain. He emphasizes ownership of material selection, process execution, cutting, embroidery, and finishing as part of his core competency. He communicates a strong focus on customization to cater to individual customer preferences.
Manufacturing Process: From Material to Ready Product
The production flow begins with sourcing and managing the material. Once the material is prepared, the process proceeds to cutting. After cutting, embroidery work is performed when required, followed by finishing steps that may include sewing and assembly. The discussion indicates that the “ready product” stage includes ironing and packing as essential final steps before the item is considered complete and ready for distribution. The finished and packed products are then distributed to various sales channels.
Finishing: Ironing, Packing, and Distribution
Ironing is explicitly mentioned as part of the finishing touches, along with packing. After packing, the products are routed to wholesalers and other distribution channels. The note indicates that the packaged products are allocated to different destinations, including winter-season markets, suggesting regional or seasonal distribution considerations.
Product Range and Customization
A central theme is customization: almost every aspect of the kurti—fabric, design, size, and fit—is customizable. The factory handles variations in design according to each customer’s specifications, which is described as a major challenge but also a key competitive advantage. The sizes offered are broad, with references to a range extending up to very large sizes (e.g., XYZ, 5XL). The customization scope includes fabric selection (discussed below) and size customization, allowing customers to specify exact requirements. In practice, the manufacturing process is guided by the customer’s design and fabric preferences, and adjustments are made accordingly.
Fabrics and Seasonal Strategy
The discussion centers on cotton-based fabrics as the predominant base, with mentions of other options such as “flex” (likely blends or stretch fabrics) and possibly linen or wool for different seasons. Cotton-based fabrics are cited as the most common, with regular and light-weight variants suitable for various designs and wearability. The vendor highlights seasonality as a crucial factor: winter offerings may include heavier or different blends, while cotton remains prominent in other seasons. There are references to using wool in winter and shifting fabric choices in response to seasonal demand, including the potential use of other fabrics like linen in appropriate seasons. The fabric choice is closely tied to the design requirements, weight considerations, and customer preferences.
Design and Customer Alignment
A key challenge emphasized is understanding and translating each customer’s unique design into a manufacturable product. This requires close collaboration with customers to capture their design intent and fabric choices. The designer’s role, along with the fabric base, is pivotal in defining the final look and feel of each kurti. Customization extends to detailing, finishes, and fit across a wide size range, necessitating flexibility in cutting and sewing to meet varying specifications.
Sales Channels and Marketing
Finished products are sold via both online and offline channels. Online presence includes platforms such as social media (e.g., Instagram) and Facebook, while wholesale channels and other wholesale-style platforms are also used. The interview notes an ongoing process of subscribing or updating the product designs on these platforms, reflecting a dynamic approach to marketing and product updates. The emphasis is on reaching customers via multiple touchpoints, including direct customer interactions and wholesale networks.
Economics: Pricing, Profit, and Operations
A practical financial note is that profit margins are kept at a minimum to ensure smooth operations from production to delivery. This approach suggests a focus on high-volume or efficient processes to maintain a healthy working cycle, with attention to cost control across materials, production steps, finishing, and distribution. The emphasis on a lean profit model indicates a preference for sustaining operations and fulfilling orders consistently rather than pursuing very high margins.
Acknowledgments and Feedback
The interview closes with appreciation for Mohammad Shyam, who has provided feedback since childhood. The host expresses gratitude for the time and input given, underscoring the value of ongoing mentorship and practical guidance in developing the business.
Connections to Broader Themes and Implications
In-house production versus outsourced job work: The shift toward owning the full process aligns with greater control over quality, lead times, and customization, but requires investment in equipment, skilled labor, and process discipline.
Customization as a business model: The ability to tailor fabric, design, and size to individual customers positions the business to capture niche demand, but this comes with complexity in design validation, material sourcing, and production planning.
Seasonal planning and fabric strategy: The emphasis on seasonality highlights the need for flexible supply chains, inventory planning, and fabric options to meet changing demand.
Multi-channel distribution: Combining online (social media, wholesale platforms) with offline channels enables broader market access but requires integrated marketing, order management, and customer service.
Economic viability: A lean profit approach suggests prioritizing efficient operations and scalable processes to sustain growth in a competitive apparel market.
Practical Takeaways
Move toward end-to-end control of production to improve quality and customization responsiveness.
Build a robust fabric and supplier base that supports seasonal variation and design flexibility.
Develop clear processes for each production stage: material sourcing, cutting, embroidery, sewing, finishing, ironing, packing.
Maintain an adaptable size range and a system that can accommodate highly customized orders while controlling lead times.
Leverage multiple sales channels, with synchronized marketing and design updates across platforms like Instagram, Facebook, and wholesale marketplaces.
Keep a lean pricing strategy to ensure operational sustainability and steady cash flow.
Summary
The interview presents a hands-on portrait of a Mumbai-based kurti manufacturer who transitioned from outsourcing to in-house production to gain control over design, fabric, and customer customization. The process arc—from material selection through cutting, embroidery, finishing, ironing, and packing—culminates in distribution to wholesalers and online/offline customers. The business emphasizes customization, seasonal fabric choices, broad sizing, and lean profit margins, all while leveraging multiple sales channels. Acknowledgment of mentorship and feedback rounds out the practical, experience-driven approach to building a boutique manufacturing operation.