Dürkopp Adler Automatic Pocket Setter in operation
The in-house garments factory successfully operates more than one shift/day to optimise the capital productivity for high cost automates.
Our factory embodies the experience learnt during start-up from leased line operations and involves investment in automates and superior technologies critical to quality areas and operations requiring de-skilling for consistency of product.
People
A team of experienced and qualified managers forms the foundation for meeting commitments through knowledge, creativity and innovation in processes. The team is young, professional, and highly responsive to satisfying changing customers needs.
Production Executives – Training in Progress
A local work force has been employed after administering stringent tests designed by a European consultant on dexterity and co-ordination with supervision from 20 production executives who have been trained on sewing and shop-floor management for two continuous months. The operators have undergone a modular training course on sewing for three months to imbibe the best sewing practices.
Processes
The entire team has worked with the consultants on implementing processes and systems aimed at zero defects and to make the product “right first time”.
We follow stringent sampling and quality control systems throughout the manufacturing cycle. All incoming fabric is checked for suitability.
The facility has self-managed U-Cell modules for assembly and are designed to be flexible and multi-skilled for variations in product styles and unique customer requirements.
INFRASTRUCTURE
Lectra Automatic Cutter – Vector Fashion 500
Cutting
Surya Nepal’s facility is the only facility in the country utilizing the strength of sophisticated Lectra CAD/CAM equipment along with accompanying digitizer, plotter and Optiplan software for planning.
Sewing
Shop Floor – Sewing Area
For ensuring precision in sewing, the critical areas are fully automated with Dürkopp Adler pocket setters and template guided cuff/collar attach workstations. To give an impeccable quality to the product, we use fully programmable electronic sewing machines armed with UBTs and automatic pressure foot lifters assisted by Ngai Shing collar cuff turning, trimming and blocking machines.
Finishing
Macpi, Italy, is the backbone for our finishing operations, combining body press with inflatable dummies to give a crispier finish to the body. It is the only machine of its kind in the country. Microprocessor-based collar and cuff presses and vacuum tables accompany it.
Information Technology
Information Technology is leveraged to provide the maximum level of user enablement.
