ApparelApparel Production in Georgia

Embed Size (px)

Citation preview

  • 7/27/2019 ApparelApparel Production in Georgia

    1/47

    Greenfield Investment

    Apparel Production in

    Georgia

    Transaction Services

    Opportunity

    18January 2012

    Strictly Privateand Confidential

    See important notice onthe next page

  • 7/27/2019 ApparelApparel Production in Georgia

    2/47

    Important Notice

    Partnership Fund (PF).

    The attention of recipients of this document is drawn to the comments inthe letter to PF in the document. We emphasize that the information in

    the Report is, in general, as at December 2011 or earlier and thus is out ofdate.

    Provision of this document to recipients, other than PF, is intended onlyfor information purposes and it does not represent any form of

    PwCApparel Production in Georgia Greenfield Invest ment Opportunity

    investment advice or recommendation by PwC to any such recipient orany other person. PwC accepts no duty of care (whether in contract, tort

    (including negligence) or otherwise) to any person other than PF.

    03 October 2012

  • 7/27/2019 ApparelApparel Production in Georgia

    3/47

    18 January 2012

    JSC Partnership Fund15, Tamar Mepe Avenue,Tbilisi 0112 ,

    Dear Sirs,

    In accordance with our contract with you dated 22 October 2011 (the Contract), we provide you with the report on the Apparelindustry (the Report).

    The Report has been prepared solely for you and the project purposes referred to on the next page. You may not make copies ofthis report available to other parties except as described in the Contract, and subject to the conditions described therein. We willnot accept any duty of care (whether in contract, tort (including negligence) or otherwise) to any person other than you.

    We draw your attention to important comments regarding the scope and process of our work, set out immediately following thisletter.

    Under certain circumstances, PwC may receive a success fee if it finds investors for the project.

    If ou re uire additional clarification on an of the matters included in our re ort lease do not hesitate to contact Yuri Dolidze.

    Daneil CappellettiPartnerT: +420 251151 250F: +420 251 156 [email protected]

    Altaf TapiaPartnerT: +995 32 2508 (061/561)F: +995 32 250 80 [email protected]

    Yuri DolidzeDirectorT: +995 32 250 80 62F: +995 32 250 80 60

    [email protected]

    Yours faithfully,

    PricewaterhouseCoopers Central Asia and Caucasus B.V. Georgia Branch; Address: #7 Bambis Rigi Street, Business Center Mantashevi,Tbilisi0105, Georgia, T: +995 (32) 250 80 50, F:+995 (32) 250 80 60, www.pwc.com/ge

  • 7/27/2019 ApparelApparel Production in Georgia

    4/47

    Scope and Process

    Scope Process

    Scope of our work The scope of our service is an independent conceptual study of the potential Greenfield projects in the Apparelindustry having the following business model Contract manufacturing of clothes from fabric. A description ofthe sco e is rovided in A endix 2 which has been extracted from the Contract.

    Access t o information The Report is based on publicly available information, PwC search engines, other secondary data, industryspecialists and knowledge of the industry gathered and/or used during its preparation as part of the analytical

    work.

    Basis of our work We have not carried out anything in the nature of an audit, due diligence, valuation, nor, except where otherwisestated, have we subjected the financial or other information contained in this report to checking or verification

    procedures. Accordingly, we assume no responsibility and make no representations with respect to the accuracyor completeness of the information in this report, except where otherwise stated. Our work did not involve specialengineering, technical or legal qualification.

    Important notice As described in the Contract, this Report is intended to be used, among other supporting materials, by us and PFin discussions with various third parties such as, without limitations, fund providers or other third partiesrelevant for the purposes of the project (Potential recipient). Provision of Report to Potential recipients isintended only for information purposes and it does not represent an investment advice or recommendation to itsemployees or advisers. Therefore, items of possible interest to any Potential recipients may not have beenspecifically addressed for the purposes of the Report.

    Any Potential recipient shall comply with applicable copyright and other third party licensing requirementsrelating to his use of this Report. Any Potential recipient is also required to ensure that any notice or disclaimerand any copyright notice included in the Report are incorporated on any copy thereof. If any Potential recipientincludes any part of the Report in his own reports or any other documents, he/she shall ensure that the relevantpart of the Report is included accurately and not misrepresented in any way and any such report or documentshall incorporate any notice or disclaimer and any copyright notice included in the Report.

    For the above reasons, this report m ay not have identified all maters t hat might be of concern to you.

  • 7/27/2019 ApparelApparel Production in Georgia

    5/47

    JSC Partnership Fund ("Fund") is an investment fund established by the Government of Georgia. The Fund has over $1,5 billion worth ofasse s un er managemen

    The Fund has two main products: Insurance and Investment.Insurance is mostly applied in energy sector through guaranteeing the off take agreement liabilitiesInvestment is usually made in SPVs though preferred equity of sub-debt

    The Fund is aiming to be concentrated on four main sectors: Energy, Agriculture, Manufacturing and Real Estate.Current portfolioconsists of Transport, Oil & Gas and Energy assets.

    Objective of the Fund is to maximize risk-adjusted return.

    Fund's ultimate shareholder is the Government of Georgia.

    www.PartnershipFund.ge

    PwC 5

  • 7/27/2019 ApparelApparel Production in Georgia

    6/47

    PageOverview

    Table of Contents

    1 Project Idea 7

    2 Findings and recommendations 9

    3 Industry overview 11

    3.1 Apparel industry in Georgia 18

    4 Competitive edge of Georgia 20

    4.1 Market regulation 26

    5 Business development options 28

    5.1 Business case 29

    5.2 Sales and marketing strategy 31

    5.3 Organizational chart and staffing 33

    5.4 Financial projections 35

    6 Global apparel 38

    Appendices

    1 Glossary 44

    2 Terms of reference 46

  • 7/27/2019 ApparelApparel Production in Georgia

    7/47

    Section 1

    Project idea

    PwCApparel Production in Georgia Greenfield Invest ment Opportunity

    7

  • 7/27/2019 ApparelApparel Production in Georgia

    8/47

    Partnership Fund is inviting strategic investors to co-invest in a USD 9.5 mil.Greenfield project aiming at full service apparel manufacturing plantdevelopment

    Section 1 Project idea

    Business Case Investment Case Analysed

    T e g o a USD 44 n. appare manu actur ng n ustry un ergoessignificant changes. An increasing number of customers demandingquality products at reasonable prices with shorter lead times and valueadded services.

    The study encompasses the establishment of a Greenfield full serviceapparel manufacturing plant in western Georgia with an annualproduction capacity of six mil. pieces of wide variety of designed

    garments manufactured for global wholesalers and retailers undertheir private labels.

    The business is aiming to leverage Georgias unique position in termsof:

    1. Availability of affordable and qualified workforce

    2. Location - proximity to markets and sourcing destinations withdevelo ed infrastructure and trans ortation s stem

    T e nvestment requ rement stan s at USD 9.5 m . F nanc ngstructure considered is as follows:

    1. TheInvestors contributionof USD 2.4 mil. in common equity

    2. Partnership Funds matching contributionof USD 2.4 mil. inpreferred equity

    3. Debt of USD 4.7 mil. acquired with the assistance of Partnership

    Fund (if needed)

    30% of investment is allocated to the production facility development.the remaining 70% covers initial working capital requirements .

    PwC

    3. Liberal business environment and preferential terms of access tokey regional markets

    4. Government support

    5. Availability of competitively priced inputs (energy, water, etc.)

    ... to enjoy shorter lead times, competitive quality and lower cost baseadvantage for western markets compared to major Asian sourcingdestinations.

    Investment Return Indicators (USD mil.)

    Common Equity Holder NPV 3.1

    Project NPV 7.2

    Project IRR 25%

    Payback Period 5 Yrs.

    Discounted Payback Period 7 Yrs.

    8Apparel Production in Georgia Greenfield Invest ment Opportunity

  • 7/27/2019 ApparelApparel Production in Georgia

    9/47

    Section 2

    Findings and recommendations

    PwCApparel Production in Georgia Greenfield Invest ment Opportunity

    9

  • 7/27/2019 ApparelApparel Production in Georgia

    10/47

    Recommendations

    Section 2 Findings and recommendations

    Business Viability Findings Pg.

    Market Viability Global USD 448 bn. apparel manufacturing industry is expected to grow ca. 3% in 2011 and medium termforecasts are favourable too. The industry undergoes significant changes, such as: strengthening pressure on

    cost of production and lead times. Georgias location, availability and costs of quality workforce and energycreates opportunities for international players to gain competitive edge over Asian counterparts and supplywestern markets, namely Europe. In addition, most west ern markets impose smaller regulation and tariffs toapparel imports from Georgia compared to imports from most Asian countries.

    8-18, 30-32, 34

    Technical Viability Organized apparel manufacturing in Georgia dates back to the beginning of 20th century. A number ofinternational and local apparel companies with diversified customer portfolio are already operating inGeorgia

    As all of key raw materials (fabric, buttons, threads, labels, zippers) can only be sourced from outside ofGeorgia, because there is no local production, the total cost of sourcing possesses some challenge to thebusiness to be competitive on a global marketplace

    The manufacturing facility can be developed using used equipments (from closed factories in Europe forexample) that could bring investment requirement down to 50%

    13, 15-16,22, 24, 33

    Business Model Viability Full service apparel contract manufacturing that accesses markets through intermediaries is a welldeveloped and established business model in the industry globally

    10

    Economic and FinancialModel Viability

    The project has a positive NPV of USD 10,4 mil. over 10 years span . The investment yields a 39% IRR (forthe common equity investor). Investment payback period is 4 years.

    25-26

    PwC

    Recommendations Key to attracting investors is development of a business environment that brings significant competitive advantages compared to competing destinations

    - E.g. Georgia should consider reaching preferential trading terms on apparel with US (largest apparel market) as enjoyed by Mexico and several central and southAmerican countries, and with Japan (3rd largest importer of apparel) as enjoyed e.g. by Indonesia.

    10

    Management Model andExit Strategy Viability

    Bringing in a strategic investor as considered by the Partnership Fund should enable unwindingestablishment and developing needed industry contacts rapidly

    5

    Apparel Production in Georgia Greenfield Invest ment Opportunity

  • 7/27/2019 ApparelApparel Production in Georgia

    11/47

    Section 3

    Industry overview

    PwCApparel Production in Georgia Greenfield Invest ment Opportunity

    11

  • 7/27/2019 ApparelApparel Production in Georgia

    12/47

    Global apparel manufacturing is forecast to generate revenue of USD 448.5 bn.in 2011, a 3% increase over 2010. Global production is concentrated in Asia

    Apparel Manufacturing Turnover, 2011

    Section 3 Industry overview

    AsiaUSD 260,1 bn.

    EuropeUSD 132,3 bn.

    North America

    USD 22,4 bn.

    Africa & MiddleEast

    PwC

    Source: IBIS

    South America

    USD 22,4 bn.

    , .

    OceaniaUSD 2,2 bn.

    12Apparel Production in Georgia Greenfield Invest ment Opportunity

  • 7/27/2019 ApparelApparel Production in Georgia

    13/47

    China is the main exporter in apparel industry accounting for 40% of the globalexport, USA being the leading importer. International trade in apparel isgrowing steadily at 2.5% CAGR (2007-2011). The forecast is that during next 6

    years average growth rate will be 3,8 % annually

    Top Exporters (USD mil.) Top Importers (USD mil.)

    Section 3 Industry overview

    Global apparel trade in USD bn., 2007-2011

    Source: Comtrade, PwC analysis

    China 121,072 40%

    Italy 18,505 6%

    Turkey 12,382 4%

    India 10,604 3%

    France 9,221 3%

    Indonesia 6,501 2%

    Others 125,115 41%

    USA 75,647 25%

    Germany 32,693 11%

    Japan 25,262 8%

    United Kingdom 21,959 7%

    France 20,357 7%

    China, Hong Kong SAR 15,709 5%

    Others 111,773 37%

    PwC

    268.8 278.7 282.3 296.1 303.4

    0

    50

    100

    150

    200

    250

    300

    350

    2007 2008 2009 2010 2011

    USD

    bn.

    Source: IBIS, PwC analysis

    CAGR 2.5%

    13Apparel Production in Georgia Greenfield Investm ent Opportunity

  • 7/27/2019 ApparelApparel Production in Georgia

    14/47

    The apparel industry consists of seven basic lines. Key segment at ca. 59% ofthe market is womens and girls wear

    Primary apparelcategories: Product revenue split by customer group,2011

    Section 3 Industry overview

    Manufacture of

    Children'sand baby

    clothes

    Coats andwinter

    clothes

    LeisureSuits for

    Workclothing and

    ethnicclothes 37%

    59%

    Men's and boys' wear

    Other apparel

    Women's and girls'wear

    PwC

    clothes

    NightwearSportswear

    women 5%

    Source: IBIS

    14Apparel Production in Georgia Greenfield Invest ment Opportunity

  • 7/27/2019 ApparelApparel Production in Georgia

    15/47

    Different market segments have different needs and success in marketplacedependent on businesses ability to adjust to changing needs effectively

    Segmentation by Type

    Perform manufacturing

    Section 3 Industry overview

    aute outure

    Dior, Chanel, Armani

    Ready to Wear/Designer

    Chanel, D&G, Prada, Gucci

    Diffusion

    D&G, CK, Emporio Armani, Versus, Hugo Boss

    Bridge

    Patricia Pepe,Lacoste,Ann Taylor,Max.&Co.,Brooks BrothersMass Market

    Zara, H&M, GAP, Puma, Lotto, Marks & Spencer, Lebeck

    D

    egreeof

    ou

    tsourcing

    High

    Low

    Market & Typical Order Size by Volume HighLow

    w n own ac es anemployees

    Contract some or all ofthe manufacturing

    functions to other firms.

    Full package program (FPP): source materials

    High

    PwC

    Source: PwC Analysis

    and develop patterns as well as makegarments. Greater f inancial responsibility.

    Cut-make-trim (CMT) contactors: supplyoperators, machines, and thread and makegarments.

    Specialty contractors: provide services such aspattern grading, cutting, embroidering, beltmaking, fabric pleating, or screen printing.

    LowHigh

    Orderdifficultylevel

    Price Range

    Large customers (like Zara, Gap, etc.)basically demand CMT services with

    large orders and little value added

    Smaller brands and retail chains areafter FPP services with smaller ordersand greater value added

    Order Size (volume)

    15Apparel Production in Georgia Greenfield Invest ment Opportunity

  • 7/27/2019 ApparelApparel Production in Georgia

    16/47

    The biggest share of value in apparel industry is captured by retailers (ca. 65%of retail value). Ca. 11% - is captured by apparel manufacturers

    Section 3 Industry overview

    Apparel value chain

    7%

    11%

    1% 2% 13%

    65%

    100%

    0%

    10%

    20%

    30%

    40%

    50%

    60%

    70%

    80%

    90%

    100%

    supplier manufacturerAgent Transportation Wholesaler Retailer Total value

    PwC

    Prices LabourEnergy

    R&D Marketing

    Keys areas forcompetiveness

    PriceQuality

    PriceQuality

    PriceOrders ScaleQuality

    PriceTime Options

    PriceQualityService

    BrandPrice

    Concentration Low Low Low Medium Medium Low

    Source: PwC Analysis

    16Apparel Production in Georgia Greenfield Invest ment Opportunity

  • 7/27/2019 ApparelApparel Production in Georgia

    17/47

    Differentiation in apparel is limited. Apparel manufacturers have to competebased on costs. Cost of material accounts for majority of the total costs andcomprises on average 56 % of the apparel manufacturings costs

    Section 3 Industry overview

    58%

    18%14%

    3% 3% 2% 2%

    0%

    10%

    20%30%

    40%

    50%

    60%

    70%

    Purchases Wages General & Other Rent Depretiation Interest Taxation

    Global apparel industry typical cost structure, 2011

    Source: IBIS

    PwC

    Purchases include materials such as fabrics, yarns, textiles, lace, buttons, zippers and so on.

    The industry is labour intensive; labour costs account for an estimated 18% of revenue. This is down from approximately 19.0% in 2006.

    General & Other costs include administrative and marketing costs.

    17Apparel Production in Georgia Greenfield Invest ment Opportunity

  • 7/27/2019 ApparelApparel Production in Georgia

    18/47

    Section 3.1

    Apparel industry in Georgia

    PwCApparel Production in Georgia Greenfield Invest ment Opportunity

    18

  • 7/27/2019 ApparelApparel Production in Georgia

    19/47

    Organized apparel manufacturing in Georgia dates back to the beginning of20th century. Industry collapsed after the breakdown of Soviet Union in early1990s. Qualified personnel of that time is still available. Number of local andinternational apparel companies with diversified customer portfolio areoperating in Georgia

    Section 3.1 Apparel industry in Georgia

    Local apparel manufacturers in Georgia

    NameParent

    companyEstablished

    Number of

    employees

    Revenue

    (USD mil.)

    BTM TextileATK Textile /

    Turkey2006 600 6.1

    Adjara TextileMilteks Tekstil

    / Turkey

    2009 487 1.0

    Georgian Textile - 2006 280 0.8

    LTD Apparel

    Manufacturing Factory- 2010 220 -

    Mileri - 2011 170 1.8

    163 small scale apparel manufacturers mainly servicing custom orders on localmarkets

    Source: PwC Analysis

    KAKHETIIMERETI

    KVEMOKARTLI

    GURIA

    MTSKHETA-

    MTIANETI

    RACHA-LECHKHUMI

    AND

    KVEMOSVANETI

    SAMTSKHE-

    JAVAKHETI

    SAMEGRELO-

    ZEMOSVANETISokhumi

    ABKHAZI

    A

    ADJARA

    Batumi

    Ambrolauri

    Akhaltsikhe

    Georgia TskhinvaliBlack Sea

    0 25 50 75 Kilometers

    75 Miles50250

    Senaki

    Poti

    Sarpi

    Samtredia

    Vale

    Kartsakhi

    SOUTH

    OSSETIA

    Tbilisi

    Larsi

    Sadakhlo

    RedBridge

    Lagodekhi

    TelaviGoriZestapho

    niKhashuri

    Zugdidi

    Kulevi Kutaisi

    - Factory

    PwC Source: GeoStat

    Apparel Trade Data for Georgia (USD mil.), 2010

    Country Import Export

    Turkey 21,6 12,7

    China 12,7 -

    Italy 3,4 -

    France 3,0 0

    Germany 1,8 0,5

    United Kingdom 0,5 -

    Others 7,5 0,1

    Total 50,5 13,3

    0

    50

    100

    1980 2006 2007 2008 2009 2010

    Appare manu actur ng n Georg a, stor cdevelopment

    Apparel Manufacturing in Million UnitsSource: Soviet Encyclopaedia, GeoStat, PwC analysis

    CAGR (for 2006-2010)27,8%

    Apparel Production in Georgia Greenfield Invest ment Opportunity

    19

  • 7/27/2019 ApparelApparel Production in Georgia

    20/47

    Section 4

    Competitive edge of Georgia

    PwCApparel Production in Georgia Greenfield Invest ment Opportunity

    20

  • 7/27/2019 ApparelApparel Production in Georgia

    21/47

    Fabric and other supplies constitute 56% of total costs. Proximity and access tomajor supply destinations (Turkey, Italy) gives the potential Georgianmanufacturers competitive edge

    Section 4 Competitive edge of Georgia

    Cotton price trend (USD cent per pound), 2006-2010

    Average CIF Price of Fabric in InternationalTrade (USD/m), 2006-2010

    0

    2040

    60

    80

    100

    120

    140

    160

    2006 2007 2008 2009 2010

    Source: USDA, PwC analysis

    Currently local manufacturers in Georgia are sourced from Turkey

    -

    24

    6

    8

    10

    12

    14

    16

    2006 2007 2008 2009 2010

    CAGR 4%CAGR 23,2%

    PwCApparel Production in Georgia Greenfield Invest ment Opportunity

    As all of key raw materials (fabric, buttons, threads, labels, zippers) can only be sourced from outside of Georgia, because there is no localproduction, the total cost of sourcing possesses some challenge to the business to be competitive on a global marketplace

    21

  • 7/27/2019 ApparelApparel Production in Georgia

    22/47

    Labour cost represents 17% of total production costs. We see a trend ofincreasing wages in main producing countries. The low cost yet educated labouravailability and high unemployment rate along with liberal labour legislation

    and low level of unionization makes Georgia an attractive destination forapparel manufacturing

    Section 4 Competitive edge of Georgia

    0 1,0002,0003,0004,0005,000

    Morocco

    Armenia

    Uzbekistan

    Georgia

    China

    Bangladesh

    Ukraine

    Belarus

    AzerbaijanIndia

    Turkey

    Greece

    Italy

    France

    Germany

    United Kingdom

    USA

    Average monthly wages(USD)

    0% 10% 20% 30% 40%

    BelarusUzbekistan

    ChinaBangladeshAzerbaijan

    GermanyUnited Kingdom

    ItalyArgentina

    UkraineFrance

    USAIndia

    GreeceMorocco

    IranTurkey

    GeorgiaArmenia

    Relative unemployment2010

    0 % 2 0% 40 % 6 0% 80 %

    Bangladesh

    China

    India

    Turkey

    Armenia

    Azerbaijan

    Georgia

    Ukraine

    Germany

    Italy

    France

    UK

    USA

    % involved inTertiary Education

    0% 50% 100%

    Bangladesh

    Morocco

    India

    Turkey

    China

    Chile

    Greece

    ItalyAzerbaijan

    USA

    United Kingdom

    Germany

    France

    Armenia

    Ukraine

    Belarus

    Georgia

    Literacy rate 2010

    PwC

    The largest group of unemployed, ca. 50% is aged between 20-34 years

    Salary levels differ across Georgian regions. The highest average salary is in Tbilisi (ca. 25% above the national average), in regions weanalysed as a potential location for the apparel factory an average salary level is 25-30% below country s average.

    Labour legislation is one of the most liberal in the region

    Level of unionization is low

    The average number of workers in one establishment worldwide is 60-70 employee.

    The average salary globally in this industry is USD 700. In Georgia this would be 450 less, USD 250.

    Source: Wordlbank; ICIA, PwC Analysis

    Apparel Production in Georgia Greenfield Invest ment Opportunity

    22

  • 7/27/2019 ApparelApparel Production in Georgia

    23/47

    Georgia has a stable and secured energy supply which is cost competitive

    Section 4 Competitive edge of Georgia

    0.12Cost of electricity USD/kwh, 2010

    2.6Cost of natural gas USD/m3, 2010

    0.00

    0.02

    0.04

    0.06

    0.08

    0.10

    TK CN IN RU AZ AM KZ GE PK US EG0.0

    0.2

    0.40.6

    0.8

    1.0

    1.2

    1.4

    1.6

    1.8

    2.0

    2.2

    .

    TK IN GE CN AM PK RU US AZ KZ EG

    Cost of electricity is USD 0.5 (per kwh) cheaper in Georgia compared to Turkey.

    1 2

    1

    Source: World bank; PwC analysis

    PwCApparel Production in Georgia Greenfield Invest ment Opportunity

    Cost of natural gas is USD 2.52 (m3), while in Georgia it is only 1.13.2

    23

  • 7/27/2019 ApparelApparel Production in Georgia

    24/47

    Transportation costs account

  • 7/27/2019 ApparelApparel Production in Georgia

    25/47

    Georgias location enables it to reach over 260 mil. people in medium incomecountries in two days period

    Number of Customers Reached

    Section 4 Competitive edge of Georgia

    72,921,5 7,6

    74,8

    150

    200

    250

    300

    350

    400

    450

    500

    IRRO

    BG

    TR

    UK

    64,5FR

    60,8

    82,3

    DE

    PwC 25

    4,5 3,1 8,8 5,1

    15,9

    46,0

    -

    50

    100

    - 4h 8h 13h 20h 25h 30h 35h 35h 40h 24d 25d 28d

    GE ARAZ KZTM

    Source: PwC Analysis

    Apparel Production in Georgia Greenfield Invest ment Opportunity

  • 7/27/2019 ApparelApparel Production in Georgia

    26/47

    Section 4.1

    Market regulation

    PwCApparel Production in Georgia Greenfield Invest ment Opportunity

    26

  • 7/27/2019 ApparelApparel Production in Georgia

    27/47

    Assistance Regulations

    Industry regulations vary greatly among countries. Georgia possessesadvantage of zero tariffs and duties to the European markets compared to most

    Asian counterparts

    Section 4.1 Market regulation

    Quotas Practices vary by countries. Mostly no quotas or safeguards since 2009

    Subsidies In most Asian countries governments subsidize the industry either byproviding cheap financing or export support.

    Special Regulation and Quality Control Certificate of OriginISO9001GMP

    Company specific requirements

    Average Import Duties and Tariffs Applicable to Apparel, 2011

    Exporter

    Georgia Turkey China India Indonesia

    PwC

    Importer

    France 0,00% 0,00% 11,79% 9,43% 9,43%

    Germany 0,00% 0,00% 11,79% 9,43% 9,43%Japan 9,60% 9,60% 9,60% 9,60% 0,00%

    UK 0,00% 0,00% 11,79% 9,43% 9,43%

    USA 14,26% 14,26% 14,26% 14,26% 14,26%

    Source: ITC, PwC Analysis

    27

    Apparel Production in Georgia Greenfield Invest ment Opportunity

  • 7/27/2019 ApparelApparel Production in Georgia

    28/47

    Section 5

    Business development options

    PwCApparel Production in Georgia Greenfield Invest ment Opportunity

    28

  • 7/27/2019 ApparelApparel Production in Georgia

    29/47

    Section 5.1

    Business case

    PwCApparel Production in Georgia Greenfield Invest ment Opportunity

    29

  • 7/27/2019 ApparelApparel Production in Georgia

    30/47

    We specified the case for a greenfield full service apparel manufacturing plantoffering wide variety of designed garments manufactured for globalwholesalers and retailers under their private labels

    Section 5.1 Business case

    Key characteristics Layout design

    Installed capacity 1250 pcs/h

    Land plot m2 4,000

    Buildings

    Three story building with 2,000 m2 base

    Total area (m2) 6,000

    Sampling & Pattern Making & Cutting 700

    Area for sewing 3,700

    Office Area 600Packaging & Quality Control 400

    Storage 300

    Infrastructure

    Road Connection

    Local road with connection to arterials or freewaysRailway Connection

    Optional

    Ifloor

    II/IIIfloor

    PwC 24Apparel Production in Georgia Greenfield Investm ent Opportunity

    Note: Layout is not to scale;

    30

    Location

    Poti area has the following favourable characteristics:

    Availability of labour

    Developed infrastructure (roads, sea port, Internationalairport[under construction], railway)

    Free industrial zone

    Proximity to TurkeyKAKHETIIMERETI

    KVEMOKARTLI

    GURIA

    MTSKHETA-

    MTIANETI

    RACHA-LECHKHUMI AND

    KVEMOSVANETI

    SAMTSKHE-

    JAVAKHETI

    SAMEGRELO-

    ZEMOSVANETI

    ABKHAZIA

    ADJARA

    Georgia

    Black Sea

    0 25 50 7 5 Kilometres

    75 Miles50250

    Poti

    SOUTH

    OSSETIA

    Tbilisi

    MRN

  • 7/27/2019 ApparelApparel Production in Georgia

    31/47

    Section 5.2

    Sales and marketing strategy

    PwCApparel Production in Georgia Greenfield Invest ment Opportunity

    31

  • 7/27/2019 ApparelApparel Production in Georgia

    32/47

    Full service quality offerings at competitive prices and results-orientedmarketing efforts will build up critical mass of customer orders and develop

    portfolio of loyal customers and partners

    Section 5.2 Sales and marketing strategy

    Key demand drivers in the apparel industry are: Service offering Promotion

    Disposable income of inhabitants

    Population size

    Cultural factors

    As the industry is highly commoditized it isextremely important to be competitive on keysuccess factors, namely:

    Ability to meet customers requirement onquality & price & time

    Good suppliers

    Access to low cost resources

    Effective quality control

    Economies of scale

    Capable of offering full range ofservices including design

    Best positioned to offer shorterlead times. This is increasinglydemanded by customers

    ISO 9001, GMP certified

    Business needs to consider ownbrand development in the future.However it also increases the costsassociated with advertising andmaintaining brand equity

    Apparel contract manufacturers arerarely engaged in promotionactivities through trade fairs orfashion shows. Key to new customeracquisitions in this industry arecontacts. Thus promotion activitiesfocused on agents and makingconnectionswith apparel industryplayers are vital, especially duringinitial phases of the businessdevelopment

    Pricing Distribution

    PwC

    Economies of scope important to offer competitiveprices along with quality service to

    build up customer base

    At the initial phase of the projectpromotionalpricing with discountsshould be considered

    reach markets throughintermediaries. Apparel buying

    Agents play significant role in thevalue chain. At the initial stageapparel agents residing in Turkey

    will be main targets for distributionarrangements.

    32

    Apparel Production in Georgia Greenfield Invest ment Opportunity

  • 7/27/2019 ApparelApparel Production in Georgia

    33/47

    Section 5.3

    Organisational chart and staffing

    PwCApparel Production in Georgia Greenfield Invest ment Opportunity

    33

  • 7/27/2019 ApparelApparel Production in Georgia

    34/47

    The plant will offer employment opportunities to ca. 1,500 persons

    Section 5.3 Organisational chart and staffing

    GeneralDirector

    Chief FinancialOfficer

    Sales andMarketing

    Director

    ChiefOperation

    Officer

    Designers &Developers

    ProductionLine Chiefs

    AdministrativeProcurement

    Director

    PwCApparel Production in Georgia Greenfield Invest ment Opportunity

    White Collar 75

    Blue Collar 1,411

    Total 1,486

    Salesman

    Production line chiefs

    Fashion designers

    Technical designers

    Pattern Makers

    Seamstress

    QA Staff

    Others

    Most of key personnel needs formal training orapprentice.Three weeks on-job training is sufficient for most oflow-skilled workers (Seamstress, etc.)Training for maintenance staff is delivered byequipment suppliers and included in the price

    34

  • 7/27/2019 ApparelApparel Production in Georgia

    35/47

    Section 5.4

    Financial projections

    PwCApparel Production in Georgia Greenfield Invest ment Opportunity

    35

  • 7/27/2019 ApparelApparel Production in Georgia

    36/47

    Investment requirement at USD 9,5 mil. produces common equity holders IRRof 32%. The project has positive NPV of USD 7,2 mil. The investment payback

    period is 5 years

    Section 5.4 Financial projections

    Investment requirements (USD mil.) Financials (USD mil.) Yr. 1 Yrs. 2 - 1 0

    Equipment 1.0

    Land 0.1

    Buildings 1.5

    Other 0.4

    Working Capital 6.5

    Total 9.5

    Revenue 22.7 45.4

    Operating Costs 22.8 42.6

    Finance Costs 0.7 0.7

    Net Profit (0.8) 1.7

    EBITDA Margin % 1% 7%

    EBITDA Margin (Global industry benchmark) 11%

    Operating coststructure (USD mil.)

    Amount % Investment returns indicators (USD mil.)

    PwCApparel Production in Georgia Greenfield Invest ment Opportunity

    .

    Auxiliary Materials 5.3 12%

    Utilities 0.3 1%

    Sales Commission 3.6 8%

    Labour 4.1 10%

    Fixed Costs 2.6 6%

    Depreciation 0.3 1%

    Total 42.6 100%

    Common Equity Holder NPV 3.1

    Project NPV 7.2

    Common Equity Holder IRR 32%

    Project IRR 25%

    Payback Period 5 Yrs.

    Discounted Payback Period 7 Yrs.

    36

  • 7/27/2019 ApparelApparel Production in Georgia

    37/47

    Analysis of the international apparel markets shows favourable trends

    Section 5.4 Financial projections

    Selling price and variable cost estimates are based on the apparel manufacturing industrys typical figures in Georgia

    All revenue and cost estimates are based on constant dollar approach

    Capital investment estimates are for indicative purposes and might fluctuate as much as 20% or more depending on peculiarities of detailedtechnical desi n and characteristics of area considered for the facilit develo ment

    Main assumptions

    Operating period of the project is 10 years.

    Salvage value discount factor from last year operating income is 25%

    Business is assumed to achieve an optimal capacity utilization of 80% in the second year of operations, during the first year 40% of capacityutilization is considered

    Labour salaries are USD 250 and above.

    Discount rate of 14% considered by Partnership Fund was incorporated in the analysis. Sensitivity analysis to discount rate is provided

    Analysis shows that ability to ensure costeffective sourcing of major raw materials(fabric, etc.) is vital for financialsustainability of the business.

    IRR Selling Price Change

    25% -20% -10% - 10% 20%

    -20% -3% 38% 67% 94% 120%

    -10% #NUM! 14% 46% 73% 98%

    -aterial

    hange

    Sensitivities

    PwCApparel Production in Georgia Greenfield Invest ment Opportunity

    10% #NUM! #NUM! -1% 34% 59%

    20% #NUM! #NUM! #NUM! 13% 41%RawCost

    IRR Selling Price

    25% 9.5$ 10.0$ 10.5$ 11.0$ 11.5$

    -20% 30% 44% 58% 72% 85%

    -10% 27% 42% 56% 70% 83%

    - 25% 40% 54% 68% 81%

    10% 23% 38% 52% 66% 79%

    20% 21% 36% 50% 64% 77%FixedCost

    Change

    37

    -3000

    2000

    7000

    12000

    0% 10% 20% 30% 40%

    NPVUSD000

    Disc. RateBasecase @14% Disc.Rate

  • 7/27/2019 ApparelApparel Production in Georgia

    38/47

    Section 6

    Global apparel

    PwCApparel Production in Georgia Greenfield Invest ment Opportunity

    38

  • 7/27/2019 ApparelApparel Production in Georgia

    39/47

    Global Apparel Manufacturing industry has a low level of marketconcentration. None of the large global companies account for more than 1.0%of the industry revenue. However the level of industry concentration is

    expected to increase in the future

    Section 6 Global apparel

    Selected potential customers

    Name Symbol OriginPrincipal

    MarketsTurnover USD Bn. Key Sourcing Destinations

    AdidasFWB: ADS;OTC Markets Group: ADDYY

    Germany Global 18.83India, Thailand, Turkey, China, Germany, Hong Kong,Indonesia, Mexico, Brazil, Pakistan, Taiwan

    Chicos FAS NYSE:CHS USA USA 1.713

    China, Vietnam, USA, Indonesia, India, Sri Lanka,

    Philippines, Bangladesh

    Christian Dior

    CDI:FPEN Paris, CDIF:PZPLUSMkt GrpCHDRY:USOTC US,CDI:BQEquiductCHDRF:USOTC US,DIO:GRFrankfurtCDI:TQTurquoise, CDI:EBBATS

    France Global 29.56 France, United States, Canada, and Japan

    PwC

    EuropeCDI:ROBucharest

    Coco Chanel N/A France Global 2.398 Hong Kong, China

    Dolce & Gabbana N/A Italy Global 0.987 Italy , China

    GAP NYSE:GPS USA Global 14.664 United Kingdom, France, Ireland, Korea, Japan and China

    Guess? NYSE: GES USA Global 1.19 USA, Mexico, Italy, Hong Kong

    H&M HMb.ST Sweden Global 127China, Bangladesh, India, Indonesia, South Korea,Pakistan and Sri Lanka , Turkey, Italy, Portugal,Greece, Bulgaria, Poland, England

    39Apparel Production in Georgia Greenfield Invest ment Opportunity

  • 7/27/2019 ApparelApparel Production in Georgia

    40/47

    Selected potential customers

    Name Symbol OriginPrincipal

    MarketsTurnover USD Bn.Key Sourcing Destinations

    evi Strauss & Co JSE:LVISF USA Global 4.303Argentina, Canada, China, HongKong, India, Indonesia, Italy, Turkey, UnitedStates Vietnam

    Section 6 Global apparel

    ike NYSE: NKE USA Global 19.014 China, Vietnam, USA, THAILAND.

    olo Ralph Lauren NYSE: BKE USA Global 4.979Australia/New Zealand, Central America, Korea, Hong

    Kong

    uma SEFWB: PUM

    Germany Global 3.79

    Canada, the United States, Mexico, Brazil, the CzechRepublic, Poland, Italy, Greece, Syria, Spain, Jordan,Morocco, Tunisia, Turkey, Egypt, India, Bangladesh,Vietnam, Thailand, Taiwan, Malaysia, Indonesia,

    Philippines, Singapore,rue Religion Brandeans

    NASDAQ: TRLG USA Global 0,36 USA, Mexico, Asia, Italy

    F Corporation NYSE: VFC USA Global 7.703Hong Kong, Poland and Turkey, China, Bangladesh,Vietnam, Indonesia, Thailand, Cambodia, the Philippines,Pakistan and India.

    olcom NASDAQ:VLCM USA Global 0,3 China, Mexico

    PwC

    Source: Publicly available sources, PwC Analysis

    ara

    IDEXY:US - USA; ITX:SM -Spain; IDEXF:US - USA;ITX:EB - UK; ITX:IX - UK;ITX:LI - UK; ITX:NR -UK;ITX:S1 -UK; ITX:TQ -UK;ITXS:PZ -UK; IXD:GR -Germany; IXD:TH -Germany

    Spain Global 8,1 Spain, Portugal, India, Turkey

    40Apparel Production in Georgia Greenfield Invest ment Opportunity

  • 7/27/2019 ApparelApparel Production in Georgia

    41/47

    Apparel industry players are increasingly trying to do business in countrieswith cheap labour. The key for success will be to leverage Georgias productioncompetitive advantage to eat share from main competitors

    We have studied the competition level in this industry. The fact is that As of 3rd quarter of 2011 the number of apparel manufacturing

    Section 6 Global apparel

    the number of apparel manufacturers is increasing. However it is noteasy to find contractor with good combination of price, quality andtime delivery options. The last is becoming more and more importantevery year and Georgia has a good opportunity to use its location as oneof the main competitive advantages.

    establishments worldwide is estimated around 148,726 owned byca. 132,791 enterprises.

    Our analysis indicate that average employment per establishment isca. 60-70 person.

    Selected sizable apparel producers

    Name Symbol Business Origin Key CustomersTurnover USD

    bn.No. of Employees EBIT Margin ROE ROA

    VFCorporation

    NYSE: VFC Apparel USA

    Wrangler, Lee JeansRiders, Rustler

    Chic, 20X, MaverickRock & Republic at Kohl's

    7,7 47,000 13.3% 14.8% 8.8%

    PwC

    Bosideng 3998:HK Apparel ChinaBosideng, Snow Flying,

    Kangbo, BengenShuangyu and Shangyu

    5,7 30,000 18.1% 16.4% 13.4%

    BGTCorporation

    BGT-R:TB Apparel ThailandBody Glove, People's

    market0,026 - 10.5% 19.3% 10.5%

    DevernoisSA

    DEVR:FP Apparel FranceInnos, Corte Ingles,

    Loeb0,056 - 3,6% 3,4% 2,5%

    41

    Source: Publicly available sources, PwC Analysis

    Apparel Production in Georgia Greenfield Invest ment Opportunity

  • 7/27/2019 ApparelApparel Production in Georgia

    42/47

    Technological advancement in the Global Apparel Manufacturing industry isdeemed to be low. Much of production is very labour intensive as it comprisessewing and cutting machines that need to be operated by man

    Section 6 Global apparel

    SamplingPatternMaking

    FabricCutting

    Input OutputFinal

    QualityCheck

    Packaging

    Quality Control

    PotentialSuppliers

    Origin of Supplier Contact Information

    Gerber USA www.gerbertechnology.com

    Juki Japan www.juki.co.jp

    Janome USA www.janome.com

    Equipment Needed

    Plotters

    Stitch Machines

    Cutters

    PwC

    The use of technology is increasing. For high productivity of the manufacturingprocess it is essential to use modern technologies. However, some functions aredifferent to automate and therefore will remain labour intensive in the near future.

    Jinan China www.jqlaser.comEmbroidery Sewing Machines

    Digitizers

    Flat Lock Machines

    Bar Tracking Machines

    Source: PwC Analysis

    Apparel Production in Georgia Greenfield Invest ment Opportunity

    42

  • 7/27/2019 ApparelApparel Production in Georgia

    43/47

    The top three traders (the United States, Germany and China) represent 28% ofworld merchandise trade. Asia accounts for almost 30% of world merchandisetrade

    Section 6 Global apparel

    PwC

    USD 0-250 bn.

    USD250-500 bn.

    USD 500-1000 bn.

    >USD 1000 bn.

    Source: WTO

    43Apparel Production in Georgia Greenfield Invest ment Opportunity

  • 7/27/2019 ApparelApparel Production in Georgia

    44/47

    Appendix 1

    Glossary

    PwCApparel Production in Georgia Greenfield Invest ment Opportunity

    44

  • 7/27/2019 ApparelApparel Production in Georgia

    45/47

    Glossary of terms and abbreviations

    Term Definition

    Appendix 1 Glossary

    CAGR Compound annual growth rate

    CNF Cost and Freight included

    EBIT Earnings before interest and tax

    EBITDA Earnings before interest, tax, depreciation and amortisation

    FOB Free on Board

    GMP Good Manufacturing Practice quality management system in manufacturing

    IRR Internal Rate of Return

    PwC

    ISO xxxxx Global quality management standards

    NPV Net Present Value

    Apparel Production in Georgia Greenfield Invest ment Opportunity

    45

  • 7/27/2019 ApparelApparel Production in Georgia

    46/47

    Terms of reference

    Appendix 2

    PwCApparel Production in Georgia Greenfield Invest ment Opportunity

    46

  • 7/27/2019 ApparelApparel Production in Georgia

    47/47

    Terms of reference

    Appendix 2 Terms of reference

    Objective of the assignment is to reveal business opportunities in manufacturing and agriculture fields identifiedby PF and to find investors for projects with high business potential.

    The conceptual study, covers evaluation of the business opportunities identified by PF.

    For each business field identified by PF conceptual study will include at least the following:

    1. Executive Summary

    2. Description of Products or Services

    3. Evaluation of value chain of the product/service includingintermediate and final products.

    4. Evaluation of local, regional and international markets for output,intermediate and final products including

    a. Market size and historical growthb. Regulation and legal environmentc. Potential customers/contracts and customer concentrationd. Competition at local, regional and international level

    5. Technology Considerations and investments, including evaluation ofpossible locations

    6. Marketin Strate includin

    b. Energyc. Other inputs9. Initial planning of the plant/asset (when applicable) including:

    a. Manufacturing basic design layout plan/assetb. An initial plan of the production's array and the RFI definitions for theplant/process.c. Initial planning of the transportation's system and the distribution

    chain.d. Defining critical raw materials and recommended purchasing costsagainstdestination prices.e. Defining necessary training programs for the operators.f. Produce the following documents:

    i) Civil engineering RFI

    a. Pricing andb. Distribution

    7. Organization and Staffing8. Evaluation of supplies for the product or service including

    a. Raw materials and suppliers of raw materials

    iii) Erection RFIiv) Other required RFI

    10. Financial Projections for short, medium and long term includinglocal, regional and international markets

    11. Findings and Final Recommendations

    Apparel Production in Georgia Greenfield Invest ment Opportunity