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