Some 550 soldiers are absorbed in their work at the sewing machines, as music plays in the background. Though having some form of permanent disability sustained in their days at the battlefront, they are now gainfully and happily employed at Ranaviru Apparels, a novel rehabilitation project of the Sri Lanka Army.
Ranaviru Apparels produces 50% - 60% of the Army’s annual requirement of uniforms. Commanding Officer of the project, Col. Gamini Wickramanayake said the factory turns out 1100 sets of uniforms each day, which works out to about 23,000 sets a month. “The skill of the disabled soldiers on the production line is high,” Col. Wickramanayake commented. “Their efficiency and speed is found to be higher than that of the normal workers in a garment factory.”
Pvt. S.W. Rupasinghe has worked at Ranaviru Apparels for about seven years. He was injured in a landmine at Elephant Pass in April 2000. He has an injury on his right arm and his right leg was amputated, but works as a machine operator in the assembly line at the factory. A father of two, Rupasinghe goes home to Ambanpola at the weekends. Wasantha Kumara Seneviratne, 21, who was injured in Mannar in April 2008, is now fitted with a prosthesis and also works as a machine operator. Both are comfortable at their work.
Four officers have been with the project from its inception. They had all been disabled during the war and undergone rehabilitation. The project was first proposed by Col. Wickramanayake and Major Mahesh Kumar when they were staff officers of the Directorate of Rehabilitation. Along with them, Col. Ajith Jayatissa and Major Vijitha Bandara have also been involved in the project from the start.
The main aim of the project was to find a means of keeping the large number of soldiers permanently disabled by the war, gainfully employed. Though they received their monthly salary, these soldiers, being still young, would often get depressed when they had no occupation. The Army uniforms used to be tailored by outside contractors, at a considerable cost. By establishing a garment factory to produce the uniforms, the Army not only achieved its objective of keeping the permanently disabled soldiers gainfully occupied, but also saved money for the Army.
Expert advice was obtained from relevant organizations such as the CITI, a training institute functioning under the Ministry of Industrial Development and the initial project report was prepared by the Director of CITI for a factory with 25 machines. While the machines were purchased by the Army, 45 disabled soldiers were trained as machine operators at a garment factory.
After a long period of planning and adjustments, overcoming many drawbacks, the foundation stone was laid in March 1996 in the present location at Yakkala. This land was selected because of its proximity to Ranaviru Sevana, where most of the prosthetic and rehabilitation treatments were being provided and also its easy access to public transport. Five acres of the ten-acre plot was donated free of charge by the proprietor, D.M. Pieris, while the balance was purchased for Rs. 1.5 million.
Officers and other ranks of the Sri Lanka Army contributed one day’s pay towards the cost of the project. Contributions were also received from apparel exporters’ associations while several companies donated machines and other requirements. The assistance of personnel of private garment factories was also obtained in setting up the organizational structure. A Board of Management comprising Army officers and civilian experts was appointed to supervise the functioning of the project.
A soft opening was held in August 1997, with 25 machines, located in an accommodation block. Originally a barren site, it was landscaped by the officers and factory workers themselves. The project was ceremonially opened on December 10, 1998, with 250 machines and six production lines.
Initially 350 officers and other ORs were selected by the Board for employment and given a comprehensive training, both theoretical and in-plant at various garment factories. The first officer selected for the Ranaviru Apparels was Major (now Col.) P.G.A.P. Jayatissa. Assigned to oversee the training and discipline of the soldiers, he is now the Factory Manager. Each individual’s disability is taken into consideration when they are assigned to a task.
At the factory floor, one person handles a single operation in the assembly line. Col. Jayatissa explained the process of manufacture. The required fabric is supplied by the Army, while the accessories are purchased by Ranaviru Apparels. Col. Jayatissa said they have different styles of uniforms but focus mainly on the battle dress for the soldiers in camouflage and jungle green. Daily, they turn out 1100 shirts and trousers which form the combat uniform.
In the cutting section 100 layers of cloth are laid and smoothed out and pattern boards placed on them. Col. Jayatissa explained that an anthropometrical study was conducted, taking body measurements of 12,000 soldiers. Twenty-six measurements were taken from each soldier. This study, which took two years, was conducted for the first time in Sri Lanka. “The measurements were analysed with the assistance of the Moratuwa University,” Col. Jayatissa said. “Thereafter, we introduced three size ranges, with reference to the waist size and body height.”
Lance Corporal Herath is an experienced cutter, who has been handling the job from the inception of the factory. “It is skilled work,” Col. Jayatissa said as we watch LC Herath cutting effortlessly through the 100 layers of cloth. A band knife is used to cut small components accurately.
From the Cutting Section all components are then taken to the Assorting Section, where numbers are given for each set, so that they are assembled correctly. The components are then bundled into packs of 20 for the large parts and hundreds for the small parts such as pockets, and flaps. The bundles are placed on a rack in the production line for distribution to the operators. Three sophisticated machines placed in an air-conditioned room are geared to improve production. For instance, loop attachment and pocket attachment are done by these machines in one operation. Thereafter, they are sent back to the main production area.
When the trousers and shirts are completely assembled, they are sent to the Quality Department after trimming of thread. Each piece is checked carefully at the final check point. Items with any defects are marked and sent back to the production line. Finally in the Packing Room, the uniforms are individually packed in polythene covers according to trouser waist and body height. The completed uniforms are sent to Army Ordnance for distribution to the units.
Col. Wickramanayake said an award ceremony is held annually, to encourage and motivate workers of all grades and sections. Thirty-one prizes were given for best machine operators and best supervisors at the ceremony held on April 9. The workers are also paid a production incentive up to Rs. 2,500 per month and an attendance allowance up to a maximum of Rs. 1000 per month in addition to their salary.
Warrant Officer 2, J. Ariyaratne, from the Commando Regiment has won the award for Best Supervisor for the last four years. He started as a machine operator when the factory was opened and was promoted as a supervisor after two years. Injured in an anti-personnel mine in 1993, after rehabilitation, he worked at the Ganemulla army office until he joined Ranaviru Apparels. “Even if we can’t go to war due to our disabilities, we are happy to be able to give support to our comrades by supplying their uniforms,” WO Ariyaratne said.
More than 300 soldiers are accommodated at the complex and provided with meals and all facilities. Col. Jayatissa said they enjoy medical, transport and recreational facilities, which include a library, gym, sports equipment for cricket, volleyball and badminton. A fully equipped band consisting of disabled soldiers of the factory has also been formed.
“The factory floor was planned for 250 machines,” Col. Jayatissa said. “Now we have 325 machines and it is congested.”
“We are hoping to buy a closed down factory with machines to further expand the operation,” added Col. Wickramanayake. “We plan to increase product capacity to supply 100% of the uniform requirement of the Army. We can then employ many more disabled soldiers.” |
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