Business Process Optimization

Executive Summary

“The art of optimization is to maximize the science of efficiency.” – Owais Dagra

Iqbal A. Nanjee & Co. conducted a thorough study and report on Stallion Textiles various initiatives with respect to Business Process Optimization.  The findings in the report are based on comprehensive due-diligence on the global textile spinning sector along with  a detailed examination on Stallion Textiles operations collected through numerous surveys, physical inspections of the facilities including plant and machinery, interviews with corporate/mill management and an in-depth business assessment of the Project’s concept, its commencement, evolution and achievements.

Stallion Textiles is one of the largest textile spinning mills in the world comprising of 156,000 spindles, producing 30/1 PC (Polyester Cotton) carded yarn. Stallion Textiles is located in Pakistan with an 800,000 sq ft. all encompassing self contained, state-of-the art infrastructure on 12 acres.

The report finds Stallion Textiles to be the most cost efficient textile spinning mill in the world, which has resulted from successfully achieving extra ordinary benchmarks with respect to 12 key initiatives, that in combination have resulted in Stallion comprehensively attaining the highest levels of sustainable Business Process Optimization.

The Project History

Opportunity Creation Phase – Business Process Innovation

Stallion, in accordance with The Dagra Model, commenced the initiation of the Opportunity Creation Phase – Business Process Innovation in 2003. As part of the strategy, it was decided to initially install a 15480 spindle unit to get acclimated with the details of the business processes and innovate opportunity creation.

In early 2006 the plant was operational and Business Process Innovation commenced with identification of both micro and macro areas for opportunity creation ranging from capital expenditure to all major and minor line item expenses. Cost efficiencies and economies of scale research and analysis were also conducted both locally and internationally.

By 2007, the R&D was completed and Stallion was ready to expand the size of its operation entering into the Platform Phase of Business Process Optimization. In 2008, the plant was expanded to its current size of 156000 spindles and operations recommenced in early 2009.

Platform Phase – Business Process Optimization

During this phase, 12 key initiatives were undertaken, as detailed in Section 4, with respect to Business Process Optimization establishing the platform that would catapult Stallion into the Growth Phase of leveraging opportunistic strategy.

Business Process Optimization

Stallion’s Business Process Optimization has been successfully attained as a result of focused initiative in the following key areas that have all combined to create a sustainably unique mega textile spinning business model:

  • Infrastructure Quality and Efficiencies
  • Technical Reengineering
  • Process Reengineering
  • Energy Efficiencies
  • Continuous Operations
  • Innovative Mill Management Model
  • Production and Quality Enhancements
  • Operating Cost Efficiencies
  • Ongoing R&D Commitment
  • Efficient Corporate Structure
  • Centralized Operational Control
  • Sustainably Unique Mega Textile Spinning Business Model

Report Findings

With the support of the “Dagra Business Model – The Inverted Pyramid” and bringing into practice the 12 key initiatives with respect to the Business Process Optimization, Stallion Textiles has successfully  achieved the goal of establishing a mega size textile spinning project with the capability to deliver consistent and acceptable quality products to a broad customer base and is in its Growth Phase through a well planned Opportunistic Strategy.

Stallion has successfully completed various phases of planning, innovation, integration, market positioning, optimization of the plant and machinery utilization on a 365 day basis, optimum production and consistent quality yarn manufacturing for all segments of the p/c textile weaving/knitting base in the country while also achieving the highest levels of capital/operational cost efficiencies unlikely to be matched by competitors

This is a unique blend of attributes which ensure Stallion’s consistent growth in the future with robust profitability.