Hirdaramani Industries Ltd. is one of the largest apparel factories in Sri Lanka, exporting woven garments since 2000. It produces garments for brands such as Levi's, Penguin, Adidas, and Columbia. The document analyzes Hirdaramani's current product design and production process for a fly pocket garment produced for Columbia. It identifies strengths like quality awards and job security, and weaknesses like machine breakdowns and differences in employee attitudes. It recommends appointing staff to supervise machines, introducing automated efficiency systems, relocating the washing plant, providing uniforms for employees, and implementing training programs.

1. Product Design & Process
Analysis of
Hirdaramani Industries Ltd.
Presented By : Group 01
Department of Decision Sciences

2. Content
Current Product & Process Analysis
Theory into Practice
Strengths & Weaknesses
Fly Pocket
Recommendations
Introduction to Hirdaramani

3. Hirdaramani Industries Ltd.
• One of best apparel factory located in Kahathuduwa, Sri Lanka by
exporting woven garments since 2000.
• The biggest markets for Hirdaramani garments are the USA, UK
& EU countries & mainly produces garments under reputed labels
like Levi's, Penguin, Adidas, Columbia, etc.
• Hirdaramani runs 45 production lines with the capacity of 1
million pieces per month.
• Hirdaramani mainly use Tuka Tec system for pattern and marker
making, EDI, Microsoft Dynamics ERP as their technologies.
• Hirdaramani Group has open up their branches in Bangladesh &
Vietnam in order to increase their market share & achieve several
national & international awards due to their excellence business
performance.

4. Fly Pocket
• Selected Garment Item which labeled under the Columbia Brand.

5. Current Production Process

6. Product Design & Process Analysis
• Main purpose is to determine & specify the product that will be
profitable to the Producer, Distributor & will give human
satisfaction.
• Tools & Techniques:
 Value Analysis
 Value Engineering
 Functional Analysis
 Standardization
 Simplification
 Make or Buy Decision
 Concurrent Engineering

7. THEORY INTO PRACTICAL
SYNARIO

8. Value Analysis
• Technique used by an industrial buyer to identify the least costly
combination of raw materials or components required to produce a
product, without any reduction in the quality of the finished good.
• Application:
 At the Procurement & Material Inspection Stage.
 At the Pattern Making & Cutting Section
 At the Production Line
 At the Washing Plant & Warehousing

9. Concurrent Engineering
• Known as simultaneous engineering, is a non-linear product or
project design approach during which all phases of manufacturing
operate at the same time - simultaneously.
• Application:
 At the Pre- Production Meeting
 At the Pattern Making Stage
 At the Production of Garments Items

10. Strengths & Weaknesses
STRENGTHS
• Won several safety & quality
awards.
• 100% job security.
• Synergetic team effort.
• Lower level idle time &
inventory handling cost.
• Trusted relationship among
sub factories.
• Better financial stability
WEAKNESSES
• Occurs machine breakdowns
due to not cleaning them
properly.
• Differences between
employees attitudes.
• Delay of line balancing at the
initial days of a new order.
• Not having proper uniform.
• Lack of automated system to
measure the efficiency.
• Remote location of washing
plant.

11. Recommendations
• Appoint the separate person to supervise the machines.
• Introduce the Automated System to measure the efficiency of each
production line.
• Closely located a washing plant.
• Introduce the uniform to the employees.
• Arrange the training & motivation programs to improve efficiency
of employees.