Technopak Apparel Forum focus on lean manufacturing, best practices

The Technopak Apparel Forum (TAF), 2012, was conducted on March 24 at
the Fortune Park Klassik, Ludhiana, with its theme “Pursuing
Manufacturing Excellence”. It had its special focus on implementing
lean manufacturing and best practices in the apparel industry.
The event was attended by representatives from the key players in the
apparel industry, including Reebok, Vardhman, Eve Line International,
Gini & Jony, Arihant International, R.B. Knit Exports, KOC Industries
and SGS.
The workshop started with the welcome speech by Mr. Amit Mishra,
Associate Director, Apparel Operations at Technopak. This was followed
by the keynote presentation on the current buzzword in the
manufacturing set-up, “Lean Manufacturing”, by Mr. Ravi Katyayan,
Principal Consultant at Technopak, and assisted by Mr. Chandrark
Karekatti, Consultant at Technopak.
A detailed roadmap was presented on the various aspects of lean
manufacturing along with its implementation in garment factories. The
concepts of single piece flow, just-in-time, continuous improvement,
error proofing, and Right First Time, among others, were explained in
detail. The presentation also explained exactly how the various tools
and processes can be applied to apparel industries. The concept of
best practices that help transform factories into world class
manufacturing facilities was also discussed.

Adequate and optimum utilization of people, processes and technology
to generate best results was advised.
The next session focused on a structured approach to ‘Quality
Improvement Process’. The session was addressed by Mr. Amit Mishra.
The thought process of the delegates was brushed up through detailed
discussion on how to improve the quality and reduce the cost of poor
quality.
The key advantages of a quality improvement programme, like reduced
non-conformance, improved workplace, defect perception
standardization, improved process flows, systems and MIS were
discussed. A structured cost-benefit analysis was also presented on
the benefits to overall business. A case study of Technopak’s
implementation of quality improvement programmes across factories in
India was also shared.
The second half of the forum was focused on inputs on the current
global apparel scenario taken by Mr. Amit Mishra. Discussions were
held on how the apparel industry has been shaping up in the last
decade and how it can be further pushed towards greater heights. The
emphasis of the discussion was on how the industry is poised as of
now, the challenges it is facing and the key success factors that
could take it forward. The challenges discussed included manpower
shortage, maintaining profitability, scale of modernization, external
competition, and low technology base and order quantities.
Insights were shared on how to beat the cost factor, rebuilding a
strategy based on product competitiveness, market diversification,
advancements in technology and building self-sustaining and
process-driven systems.
The final session was addressed by Mr. Ravi Katyayan on the topic
‘Skill Development in Apparel Industry’. The discussion focussed on
the relevance and significance of skill development as key driver for
industry growth. Technopak’s contribution to the industry through SEAM
projects was highlighted. The upcoming project to be implemented by
Technopak on ‘Integrated Skill Development’ under the aegis of MoT was
also briefed upon. Adequate stress was laid on the importance of
recruitment, training and retention strategies.
The Technopak Apparel Forum, Ludhiana, is a part of the workshop
series that addresses key challenges for the apparel industry. It was
well received by the industry participants. The next forum of TAF
series is planned in Dhaka in April.