B2B meeting and Training programme with “Strawberry Growers Association”

For Capacity building of raw material suppliers and it’s tie – ups with processing firms, a B2B meeting and training programme was organised under the SIDBI’s Cluster Development Program “Implementing BDS for MSMEs” on February 20, 2010 at Pune Fruit and Vegetable Processing Cluster.

Training programme was organised so that, raw material suppliers will get to know the requirements of processing firms – in terms of quality and quantity; get to know about post harvest and processing technology, etc.

The areas covered were Marketing tie – ups / contract farming, Quality requirements for procurement of raw material from processing firms, Post harvest technology, value added products for commercial application, linkages with cold storages, and Marketing potential and scope for strawberry cultivation in India. Experts who shared information during the event were Dr. Naikare, Shri Bipin Rewankar, Eco fresh cold storage, representatives from processing industry.

M/S Media Cura was involved in organising the event and participants were Representatives of All India Strawberry Growers Association, Representatives of micro, small and medium scale industries in the cluster, as well as BDS providers.



Seminar on “Export marketing”

With the objective to promote export at Pune Fruit and Vegetable Processing Cluster, a seminar on Export Marketing was organised under the SIDBI’s Cluster Development Program “Implementing BDS for MSMEs” on March 20, 2010.
The seminar was organised in collaboration with Mahratta Chamber of Commerce, Industries and Agriculture (MCCIA). The major areas covered were Present status of Processed Food Export and Introduction to HACCP & SPS Standards, Export marketing research, Export marketing entry, Getting ready for Exports and international trade procedures (regulatory frame work, documentation, incentives available for exports of processed

food), Opportunities for innovation in Processed Fruits and Vegetables Products for exports, Export Opportunities and New markets for Food Products, etc.
Experts who provided information were Ms. Tamanna Chaturvedi, IIFT, Shri R. G. Vaidya, Director, Synergy Research, Shri Vaibhav Nagarkar, Director, Generation Next Business Consulting, Mr. Amendra Mahamuni, Private Consultant & Mr. Vinay Oswal, Director, NAFARI. Around 50 participants attended the seminar and it was followed with question answer session.



Interactive awareness meet with ministry / directorate of MSME officials

An interactive workshop was held at Hotel “Friends regency“ on February 19, 2010 to impart information about the schemes of ministry of MSME and SIDBI to the industry stakeholders of Ludhiana. The workshop was held under the SIDBI’s Cluster Development Program “Implementing BDS for MSMEs in Ludhiana knitwear cluster. This initiative is a part of World Bank led Umbrella project “SME Financing and Development project. The main objective of the project is to make the Ludhiana Knitwear cluster more competitive by strengthening the support of Business Development Services to the MSMEs. The program started with a brief review of the activities being undertaken in the ongoing cluster development program.

It was advised that in order to tackle the problem of shortage of labor in the industry , the project has started training of females as stitching machine operators to increase their participation in the industry workforce. This training is presently running in two modules. Under the first module, the training is going on at a training center opened in the village and the girls are provided training as well as employment in the industry. The project has received immense support from FEKTAA and Bahadur Ke knitters association and they have also provided machineries to run the training center. In the second module, girls are brought to the factories and provided training on the industrial sewing machines in the firm premises and afterwards absorbed in the same factory.

The project has also done considerable work in the field of energy efficiency. Energy audits have been undertaken in some units and efforts have been made to spread awareness about energy conservation in order to increase cost competitiveness of the knitwear industry. Various workshops and training programs have also been organized to increase awareness about regulations imposed by importing countries.

Taking the program further, Mr. Nagi from MSME gave a brief outline of the program and invited the dignitaries for sharing their views. Mr. S.S. Bedi from MSME gave details of the various schemes of the ministry and how industry can take advantage of the schemes for the benefit of the industry.

Mr. Vinod Thapar, President, FEKTAAA gave a special address and appraised the industry about the skill development programs running in the cluster. He informed that the female training programs undertaken by Apex Cluster Development services are getting very good response in the industry. He has also shared the information with the Chief Minister Mr. Prakash Singh Badal and the CM has also shown interest in replicating these models.

A presentation was given by Mr. S. B. Singh on concepts of lean manufacturing in a cluster. He advised how adoption of the principles of 5 S and 3 M can benefit the industry.

The schemes of SIDBI for the knitwear industry were presented by Mr. S Sreepathy, AGM, SIDBI.

Mr. Tarun Jain , President , Bahadur Ke Knitters association advised that they have purchased land for making the office of the association and will look for a possibility of opening a common facility center at the association office. He also thanked Mr. Ashok Jain for his continuous support in the activities of the association.

Mr. Vishwabandhu, GM, District Industry Center gave an option of using government land for making a common facility center for the benefit of the industry.

The program was attended by various dignitaries and famous industrialist including Mr. Dinesh Lakra and Mr. Narinder Miglani. A special address was given by the Guest of Honor, Mr. R.C. Chopra Director MSME, Ludhiana.



Workshop on Fashion Forecast

Workshop on fashion Forecast was held at Ludhiana on March 23, 2010,. The event was attended by freelance designers and some participants from the local firms of the cluster.
The Seminar was held to make the local designers aware of the latest fashion forecast for the season Autumn Winter 2010-11. The designers from various domestic knitwear manufacturing companies participated in the program. The presentation covered the details on how forecasting is done and also on how the international fashion forecasts can be adapted by the designers creatively to adapt them to suit the local demand.

It also emphasized the importance of designing as per the latest silhouettes in vogue so that a contemporary collection can be accomplished depending on the target buyers of each manufacturing organization.

The seminar covered the various prominent agencies and websites where experienced fashion analysts scrutinize past buying patterns signs for current market dynamics and project these into the future. Activities of forecast agencies include collection of facts pertaining to consumer buying patterns, activities and occasions for which clothes are needed, their priorities, reading habits etc. This is done through liaison with stores, retailers and wholesalers and fashion professionals who also rely on information sources such as design, color and video services, newsletters, books, magazines and websites.

The expert advised that the latest materials which are going to dominate the markets this winter will be Shetland, alpaca, lambswool, cotton blends, brushed cottons, washes in various forms for upper and lower garments, basic checks, silk mixtures etc. The emphasis will be on layering of the garments as a style statement. The silhouettes will be varied from body fit to super straight leggings and fantasy inspired printed shirts will be seen. The designers working on their collections were asked to increasingly use their creativity instead of copying the designs from various websites and magazines to make their collection more effective.



Workshop on Energy Conservation Potential

A workshop was held at Hotel Friends Regency, Ludhiana on February 17, 2010 to discuss the results of the implementation of energy audits in the cluster. The workshop started with a brief review of the ongoing activities by the Mrs. Sanjeev Chaudhay, CDM. Mr Sanjiv Kale, Business Manager, Energy Audits and Utility Consultancy Division, Forbes Marshall, gave presentation on the results of the energy audits conducted in four dyeing units of the cluster. The major highlights of his presentation are as follows:

  • Cost of fuel has increased considerably even if the consumption in units is same.
  • Potential of saving in fuel cost for all units in cluster is in double digits.
  • Average saving potential in the units in which audits have been done is 27 %.
  • Discussion on ways to achieve and sustain savings and return on investment.
  • Steam accounts for 20 % of the operating cost in a dyeing unit.
  • Discussed ways and means of reducing steam cost in dyeing units.
  • Discussion on factors impacting fuel bill.
  • Findings in the cluster on boiler efficiency, feed water temperature and manual blow down.
  • Methods to improve boiler efficiency with existing equipments.
  • Impact on fuel bill by improving steam fuel ratio.
  • Average reduction of 8% in the total processing cost after implementation of recommendations.
  • Savings across other clusters were discussed.
  • Heat balance across dyeing machinery.
It was followed by an exhaustive interactive session, and queries of the industry stakeholders were answered. The program ended with a vote of thanks by Mr. Sanjeev Chaudhay, CDM.



Awareness workshop on institutionalization of Quality Management Systems

A half day awareness workshop on Institutionalization of Quality Management Systems was organized at Hotel Friends Regency in association with SGS India Ltd. on December 12, 2009. The Program started with a brief introduction about the SGS and its Consumer Testing Services Division.

The first session of the program was presented by Mr. Vinod Kumar, National sales Manager. He gave in depth information about CPSIA (Consumer Product Safety Improvement act), especially for children products specifically textiles. The trainer gave details about

1. Ban on Lead and phthalates in children products for below 12 yrs of age
2. Mandatory third party testing and certification and new safety standards
3. Lead in soft as well as hard components of products
4. Details of material specific exemptions like natural fibers, Synthetic fibers
5. Responsibility of manufacturer to comply with the guidelines
6. Limit for lead and phthalates in various products
7. Requirement of certificate of compliance for shipment to U.S.
8. Highlights in sampling for CPSIA (sample size)
9. Latest recalls from companies like Timberland and Lee.

The second session was presented by Mr Dileep Singh. He gave the details of REACH (Registration, Evaluation and Authorization of Chemicals). The presentation included details on
1. Prelude to REACH Regulations, evolution and the new phase
2. REACH impact on Textile industry
3. SGS Solution to the challenges ahead.
4. Case sharing and Compliance requirement
5. Restricted substance list



Energy Audits

Complete Energy audits were conducted in various firms under voucher cost Scheme of SIDBI’s Cluster Development Program “Implementing BDS for MSMEs in Ludhiana knitwear cluster. This initiative is a part of World Bank led Umbrella project “SME Financing and Development project”. These audits were done within time period of four months i.e. November 2009 to February 2010. Apex Cluster Development Services Pvt. Ltd. coordinated Energy audits in the cluster and Forbes marshall carried out these audits in dyeing firms and the results have been eye-opening for the manufacturing firms. The detailed energy audit at dyeing units and stitching units was aimed at savings of energy in various forms i.e., fuel, steam, light, heat etc. In some dyeing units it was found that condensate recovery factor (CRF) was as low as 43% where as it can go up to 90%. So a huge scope of savings was found in this field. Pet coke is the main fuel used in most of the dyeing units. During audit it was found that oxygen percent in stack is high by 2-2.5% in pet coke fired boiler. Most of the units are using old machines and outdated technology and are not sure about cost of steam & energy consumption under various heads & categories. Cost of steam, energy was shown & discussed with them through energy audits and workshops.



Seminar on " Waste Minimisation in Wet Processing and Production"

A seminar was organized on "Waste Minimisation in Wet Processing and Production" at TEA E-readiness center on January 27, 2010. Main objective of seminar was to provide knowledge about the scientific tools & techniques for improvement of Quality and Minimisation of the wastages in Cutting ,Processing, Sewing and Finishing Departments and maximum utilization of the resources for achieving the higher profit for the organization.

The Seminar was successful in providing broad overview among the firms participated about the cause of waste in different departments and methods of avoiding unnecessary wastages by proper inventory planning and Statistical tools to be applied in the shop floor level to control the repair and rework of operational process.



"Use of ICT to improve Organisational Efficiency"

A seminar was organized on “Use of ICT to improve Organisational Efficiency” at NIFT TEA College Seminar Hall on January 31 , 2010. The seminar focused on providing awareness about the availability of the new technological tools, which will help the garment units at Tirupur to reduce the cost and time involved in production and to improve their competitiveness.

Areas covered by experts

1.Technological advancement in Colour Communication, which will reduce the time involved in sending physical sample for approval from the buyers

2.Technological tool for developing collaborative design / product development, which will help the local designers to work with international designers to make the sample developed by the exporters are acceptable by the overseas buyers.

3.Cost effective Enterprise Resource Planning (ERP) solution for the garment industry which are suitable even to small and medium scale enterprises in the cluster, to help them to make right decision at right time and to establish effective organizational control.

The need for accuracy and speed in the highly competitive modern environment was elaborated to make the participants understand the importance of technical advancements in the industry. The usage of Information Communication Technology (ICT) was explained and clearly demonstrated in decision making as well as achieving functional competency. Live cases from the industry especially in dying, were discussed to help the firms avoid rejections, save time and reduce cost and wastages using ICT.



Seminar on "Productivity Improvement"

With the objective to provide information about Productivity Improvement for Tirupur Knitwear Cluster a seminar was organized at TEA ERC Hall on February 2, 2010. Mr. Venkat Ramani, Method Improvement consultant, delivered tools and techniques for arriving Standard Time for the Garment operations by effective time study and developed the suitable methods and tools in the Industrial Engineering techniques for the productivity improvement adhered with Work aids and ergonomics to reduce operational time / garment.

Seminar has given a brief idea about the latest tools and techniques for the productivity improvement by adopting industrial engineering concept in the garment industry. Also briefed the logic of arriving the standard time for the operation for achieving the target within the lead-time and preparation of operation bulletin for the effective control in the production.



Seminar on "Lean and Six Sigma Manufacturing Principles"

A seminar was organized to provide information to Tirupur Knitwear Cluster regarding Lean and Six Sigma Principles at TEA ERC Hall on March 2, 2010. These are modern production techniques adopted by various multinational companies all over the world to improve quality and to reduce cost, to stay competitive in today’s highly competitive market environment. The seminar highlighted the following areas:

  • Doing right things at the first time without rework and rejection
  • Exactly delivering the goods to customers’ specification with least stock without too much of logistics and handling.
  • Reducing the variation within the specification
  • Analysing the past performance and fixing the target for further improvement.
Prof. A Rajagopal, Executive In-charge for SQC & OR Unit of Indian Statistical Institute, Coimbatore, introduced various tools in Lean and Six Sigma Principles as "Keys" towards achieving better control over production to ensure quality and profitability by reducing - Reworks, Repair, Rejection etc.



Workshop for “Productivity Improvement in Garment industry”

Improving the productivity and minimizing the cost are the only ways to survive in today’s global competition. Therefore, ‘Workshop on Productivity improvement in Garment Industry’ was organized at TEA ERC, Tirupur on November 11, 2009 to sensitize the methods and tools that are available for improving the productivity in garment industry.

Mr. M. A. Sanjeevi, Ex-General Manager, Gokuldas Images Pvt. Ltd and an industrial engineer who worked in garment industry for nearly two decades, and has on hand experience in setting up number of state of art garment making units for them including one at Bangladesh, conducted the programme. In continuation of the workshop, it has also been proposed to ‘implement’ those productivity improvement tools and methods in the units, who are willing to take these principles as ‘pilots’. This programme is organized under the support of MSMEFD Project of World Bank. Considerable financial support will be extended under the project in the consultancy fees to the firms who are willing to implement those tools and techniques in their units.

The seminar has created the impact of the importance of Industrial Engineering and the application of Tools & Techniques used in the Method improvement for achieving the higher productivity. BDS have also demonstrated the case studies for the effective method of Time and Motion study. 30 Middle level Managers from various export houses have been benefited by attending the workshop and also requested to conduct the same type of workshop on periodic intervals for the benefit of the industry.



Seminar on "Personnel Effectiveness, Productivity & Success"

Seminar on "Personnel Effectiveness, Productivity & Success" was organized at TEA E-Readiness centre on December 23 – 24, 2009. Seminar created awareness about the importance of the Human Resource and the need of Training in the work place for the improvement of the systems in the organization by better Planning, Scheduling and controlling the activities effectively.

Linkages have been established with participant units to implement methods and tools for improving the effectiveness of the middle level managers and entrepreneurs in handling their subordinates to improve the productivity and to achieve the desired goal.



Seminar on "Opportunities for Product Diversification"

Even after decades of existence Tirupur Knitwear Cluster is concentrating mainly on high volume, standard cotton garments, which has low unit value realisation (UVR), even though opportunities exists to diversify its products like sportswear, swim wear and other functional textiles.
Reasons for the situation are many, like lack of awareness about the existence of market potential for such products, non availability information and technical support etc. Therefore, efforts were taken under the Micro, Small and Medium Scale Enterprises Finance and Development Project (MSMEFD Project) of World Bank, to sensitise the opportunities that are existing for the exporters

and the sources for getting technical support to manufacture such value added garment through a seminar on ‘Opportunities for Product Diversification’ at NIFT –TEA College of Knitwear Fashion between on February 21, 2010.

Dr. Mike G Bartle, President of Society for Dyer’s and Colourists, the U.K., an international expert in manufacturing sportswear and performance wear; and is associated with manufacturing sportswear for leading international brands in the category, delivered lecture on the opportunities that exists for the knitwear manufacturers in Tirupur to diversify their product. He also illustrated, how a small organization started with 6 knitting machines in the UK have grown as an organization of international repute in sportswear, by integrating all the required facilities, gradually over period. He explained that product diversification need not be on larger scale, as any one presumes; it can be started with moderate investment and by utilizing the surplus capacity that are available locally. He also informed that it was not necessary to start the business only by associating with big brands, one can work with even with smaller brands, or they can have their own brand too, considering the size of the market countries like India has.

However, he emphasized the technology involved; and the chemicals and process to be applied should be of world standard. But for that, it would be difficult to survive in the market, as it requires considering various functional aspects like moisture absorption, anti microbial, anti static aspects in the garments.

Mr. C. N. Sivaramakrishnan, Consultant for specialized finishing in Mumbai and Honorary Secretary of Society for Dyers and Colourists, India, explained various types of finishing that could be given on the garments like water repellant, fire retardant, insect repellant etc. to make them most profitable one for the entrepreneurs in the retail market.

Mr. Parvez Koatadia, Country Manager, Society of Dyers and Colourists (SDC), India explained the activities that are taken by the Society for propagating professional knowledge in colour and the efforts taken by them to support the students, institutions and the professionals to enhance their knowledge in colour; and the benefits that may accrue for the members of the Society.

Mr. S. Samiappan, President, Dyers Association of Tirupur inaugurated the seminar and explained the need for organizing such seminar to enrich the knowledge of the entrepreneurs in the knitwear cluster.

Mr. Raja M. Shunmugam, Chairman, NIFT-TEA College of Knitwear Fashion emphasized the need for inculcating such knowledge to the managers and to the students of NIFT-TEA College of Knitwear Fashion to empower them to serve to the industry better. He also advised to conduct more prgorammes in areas like Lean Manufacturing to reduce the cost of operation in the industry and to make them more competitive under the project.

Mr. S. Periyasamy, Deputy Director, Textiles Committee delivered key note address and explained the need for the industry to transform itself by adopting technological changes in every functional aspects to survive in the competition.

Mr. S. S. Sankaramoorthi, Senior Technical Advisor, Apex Cluster Development Services Pvt. Ltd welcomed the dignitaries and the participants of the seminar; and assured to incorporate the suggestions that were put forth by the Chairman of NIFT-TEA College of Knitwear Fashion in the action plan of the project for the coming years to ensure that human resources skills in the cluster become pillar stones for the growth of the Tirupur Knitwear cluster.



Workshop on condition and maintenance of garment machinery

With the objective to increase awareness among technical staff & mechanics about latest sewing machines, repair of stitching machines, reducing breakdown time & increasing production efficiency, a workshop was organized on November 21, 2009 at Hotel Friends Regency under Project “Implementing BDS for MSMEs”. The workshop was attended by 40 machine mechanics. The program started with brief overview of the project by Mr. Sanjeev Chaudhary.

Mr. Amit, Pegasus, started the presentation with a brief detail of the company and its products. Mr. Piyara Singh, Pegasus, explained about the latest attachments that stop oil leakage in sewing machines and for better needle thread loop adjustment according to fabric requirement and the thread used for stitching. Guidelines for adjusting top cover thread were displayed and explained. Also the latest models were shown where all the attachments were being used. Needle plates that provide different stitches, decorative and functional were also displayed. Also special workstation for each operation for increased productivity and uniform production were displayed e.g., special workstation for bottom hemming with specific attachments for this operation.

Mr. Manpreet Singh, Brother, gave a brief profile of the company and its products and explained about basic functioning of the sewing machine. He also explained about various machines with minimum lubrication requirement like complete dry type and semi dry type machines. Also attachments for embroidered logo attachment and placket making were shown and working of the same were explained.

Mr Supreet Singh, Jay cee Enterprises, gave tips for maintenance of machines and explained working and repair mechanism of the latest machinery. He gave a motivating presentation to the workers and explained the machinery in detail.

The program concluded with vote of thanks by Mr Harvir Singh.



Workshop on Energy Efficiency Awareness

Under Project Implementing BDS for MSMEs “Workshop on Energy Efficiency Awareness” was organized at Hotel Gulmor, Ludhiana on November 6, 2009. Mr. J. P. Thukral gave comprehensive details on the subject focusing on the several method and ways to save energy during various manufacturing processes in any industry. He advised that the emerging & rapidly expanding industrial infrastructure has ample opportunities to increase their competitiveness by applying energy efficient based practices from the outset in new industrial facilities.

The common perception holds that energy efficiency of the industrial sector is too complex to be addressed through public policy whereas it is the other way round. Of late, it has been accepted that industrial energy efficiency is dependent on operational practices, which changes in response to variations in production volumes & product types.

The topics of discussion were Energy Conservation Act 2001, Benefits Of Energy Efficiency to industry, at Country and Global level. He also provided tips for energy efficiency and electricity in maintaining electric motors, fans and blowers, compressors, pumps and boilers, light system in buildings, insulation and D. G. sets. Duties of energy manager and need for management skills in energy management were also discussed.

For benefit of firms he shared strategies and aim of energy security, energy efficiency systems like principles and objectives of energy management, energy performance assessment, types of energy audits, pillars of successful energy management and futuristic energy approach.

The event was adjudged as a good platform for resolving Queries of the participant firms regarding Energy Conservation Act. It was also an informative and motivating session for energy efficiency and energy assessment for firms.