Arvind Ku­mar & Co. – Slowly but steadily mov­ing to­wards its vi­sion

Stitch World - - PRODUCTION MANAGEMENT -

“I give you or­ders, you make it and ship it keep­ing qual­ity level as dis­cussed”. This is what a buyer’s per­cep­tion is while work­ing with a man­u­fac­turer in the ap­parel ex­port in­dus­try. But a man­u­fac­turer is al­ways con­cerned about more ar­eas than what a buyer thinks of. In be­tween get­ting an or­der from the buyer and ship­ping it, an ap­parel man­u­fac­turer has to face lot of bot­tle­necks, ma­jor­ity of them be­ing man­ag­ing the en­tire pro­duc­tion process with min­i­miza­tion of the leftovers or wastages. “These bot­tle­necks are for the man­u­fac­tur­ers not for the buy­ers which can be tack­led with ex­pe­ri­ence only. We are build­ing that ex­pe­ri­ence in our unit to sur­vive in this al­ready down­turn­ing ap­parel in­dus­try,” shares Pankaj Ku­mar Sadh.

Hir­ing work­force in an en­tirely dif­fer­ent way from the con­ven­tional sys­tem, the com­pany be­lieves in hir­ing fresh­ers or less ex­pe­ri­enced peo­ple rather than opt­ing for tech­ni­cally qual­i­fied work­force for pro­duc­tion pro­cesses. Upon ask­ing how this will cre­ate ex­pe­ri­ence in the com­pany, Pankaj com­ments, “We are aware of our work­ing at­mos­phere, there­fore, we want to ed­u­cate man­power in our own ways as we can teach a lot to the peo­ple who have the de­sire to learn new things. On the con­trary, we have a bit­ter ex­pe­ri­ence of work­ing with a work­force who have years of ex­pe­ri­ence in their do­main.”

He also avers that the com­pany can give ex­am­ple of hun­dreds of work­ers who joined the unit as new­com­ers and have now been trans­formed as skilled ma­chine op­er­a­tors over the years. “Not just sew­ing op­er­a­tors, we have pro­moted some of them as pro­duc­tion su­per­vi­sors too,” claims Pankaj. To achieve the ex­pected level of skills in its man­power, the com­pany pro­vides on-job train­ings in dif­fer­ent ar­eas such as cut­ting, pro­duc­tion, fin­ish­ing and check­ing on reg­u­lar fre­quency. “We have a ded­i­cated team of pro­duc­tion and qual­ity, whose role is to im­part

practical knowl­edge to the work­ers,” re­marks Pankaj.

But just like ‘ it’s eas­ier said than done’ prin­ci­ple, Pankaj briefs that in-depth re­search has to be done to find out "what kind of train­ing you want to pro­vide to your op­er­a­tors", es­pe­cially when one is mak­ing ar­du­ous ef­forts to sur­vive in to­day’s ap­parel in­dus­try. “Be­ing a high-fash­ion ladieswear man­u­fac­turer, we keep chang­ing prod­ucts and adding val­ues to it. Thus, ev­ery ma­jor change in prod­uct puts pres­sure on us to ar­range a tech­ni­cal know-how ses­sion for the en­tire pro­duc­tion team,” he elab­o­rates. Fur­ther­more, Pankaj says that the prod­uct change cou­pled with proper train­ing of work­force to make them un­der­stand the tech­ni­cal re­quire­ments of the prod­uct, is a suc­cess­ful way to stay in the com­pe­ti­tion.

An­other strength area of Arvind Ku­mar & Co. is its qual­ity con­trol team. The QC keeps a con­stant vigil on ev­ery stage of gar­ment man­u­fac­tur­ing, from ma­te­rial pro­cure­ment till fi­nal pack­ing. After com­ple­tion of these checks, the ma­te­rial again passes through a team of Fi­nal Qual­ity Con­trol be­fore pack­ing and dis­patch­ing of the con­sign­ments. To en­sure smooth­ness of this en­tire qual­ity check­ing process, Pankaj says that the com­pany is in­clined to­wards the use of QC tools such as Pareto Chart and Fish Bone Di­a­gram. “These tools help us an­a­lyze the root cause be­hind the chal­lenges we come across through­out the pro­duc­tion pro­cesses,” ex­plains Pankaj.

How­ever, Pankaj claims that tech­no­log­i­cal upgra­da­tion is some­thing Arvind Ku­mar & Co. is not fo­cus­ing on a large scale presently. Hav­ing in­stalled tech­nolo­gies such as three 18-heads Baru­dan com­put­er­ized em­broi­dery ma­chines and Texma ERP, the com­pany feels the present trade sce­nario is not a right time to in­vest fur­ther in au­to­mated ma­chin­ery. “As the mar­ket is al­ready go­ing down, we are wait­ing for the right time to in­vest par­tic­u­larly in one more em­broi­dery ma­chine,” con­cludes Pankaj, adding, “Till date, some­times we have to out­source a bit of or­der quan­tity hav­ing com­put­er­ized em­broi­dery but as the mar­ket regains, we have plans of in­vest­ment on cards.”

Even after adding value to a prod­uct, if the buyer asks for lesser price, we have no op­tion other than re­duc­ing em­broi­dery on the gar­ment to make it achieve its tar­get price. We try to keep the aes­thetic value more or less sim­i­lar,” says Pankaj.

“Some 700 sew­ing ma­chines to man­u­fac­ture 90,000 pcs/ month and more than 800 man­power in a 44,000 square feet com­pany are help­ing us to grow,” shares Pankaj.

Pankaj Ku­mar Sadh, Direc­tor, Arvind Ku­mar & Co.

18-head em­broi­dery ma­chine by Baru­dan is be­ing in­stalled in the com­pany

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