Lankan Army’s Ranaviru Apparels takes new strides towards the export market
View(s):By Bandula Sirimanna
YAKKALA – Two progressive apparel factories run entirely by disabled soldiers are gearing to enter the international export market.
The Sri Lanka Army’s garment units at Yakkala and Alawwa are run by soldiers disabled in the northeast conflict and these factories are currently catering to the army’s uniform requirements in certain categories, Army Chief of Staff and Chairman of the Board of Management of Ranaviru Apparel, Major General Daya Ratnayake told the Business Times at Army headquarters in Colombo last week.
Measures have been taken to upgrade the factory standards with the aim of catering to the international market , he disclosed.
Ranaviru Apparel has expanded its activities to a Rs. 850 million project, affording an opportunity to rehabilitate 1400 injured Army personnel at Yakkala and Alawwa apparel factories, he added.
However he noted that Ranaviru Apparel has to be transformed to a commercial entity from its present status of being a self-financing venture of the army with the consent of the board of directors and the Army Commander.
He said that he has directed the management of Ranaviru Apparel to explore possibilities of producing all tri-service uniform sets and uniforms for foreign armies in the future at both these factories since it would be a very profitable project for both producers and users alike.
He disclosed that with sheer dedication and commitment of disabled soldiers, the Ranaviru apparel won 2nd place in the National
Section of the factory. Pix by Mangala Weerasekera
Productivity Award for the year 2011/2012.
They also won the silver award at the National Green Award ceremony held on December 3 at the BMICH in Colombo for maintaining the factory in an environmental friendly manner promoting greener environment.
Ranaviru has also implemented the 5S systems winning the Taiki Akimoto Special Award of Excellence in 2010.
Begun 14 years ago, this factory has minimized and controlled its waste, cutting down possible costs and maximising the utilization of its existing resources.
Factory products are also expected to be exhibited at international exhibitions in the future.
This project began in 1998 by catering to 60 per cent of the army’s uniform requirements for certain styles, producing them in 32 sizes, maintaining very high quality standards, he revealed. It has also moved on to stitching other garment requirements of the army and envisages catering to 100 per cent of the army’s uniform requirement of all styles, he said.
The two factories have been upgraded and brought in line with international standards after quality of the products was raised under a new modernization programme.
The two factories at Yakkala and Alawwa, have been producing almost 70 per cent of the army’s requirement for formal uniform sets and a certain percentage of track kits and sleeping mattresses, needed for Army personnel, due to dedication and commitment of the 1400 strong workforce, he said.
What is significant is that in this factory the management and workforce consisted entirely of disabled officers and soldiers.
Every single person working there from the Factory Manager right down to the helper, has suffered permanent disabilities in the northeast war, he revealed.
Ranaviru Apparel also maintains a model village comprising the house of a disabled soldier turned farmer (Gamarala) over a one acre block of land with a farm in which vegetables, varieties of medicinal herbs and fruits are grown using manure and also irrigated from its own tank built within the premises.
The produce is sold to the staff at concessionary rates in order to, not only economize their living but also to motivate and promote them to start their own home gardening.
 Major General Daya Ratnayake |
 Rtd Lt Col Upali Gajanayake |
 Brigadier Gamini Wickramanayake |
 Miss Yohini Thevathasan |
Brigadier Gamini Wickramanayake Secretary to the Board of Management and Commandant- Ranaviru Apparel who lost his leg in a confrontation with terrorists in the north said though the factory has an army camp status, this manufacturing concern is a combination of a civil and military set up.
“Administration-wise it encompasses military disciplines whilst being a Government entity. However to ensure that this project is managed efficiently and remains self-financing, private sector accounting standards, systems and procedures and modern, quality manufacturing processes coupled with stringent training programs are adopted,” he said.
The Ranaviru apparel industry complex was set up on a 10 acre block of land partly paid for and partly donated by Meric Peiris, the owner, he said, adding that philanthropists of his calibre are rare in the country.
The project is managed by a board of management headed (by virtue of appointment) by the chief of staff and consisting of principal staff officers, in order to ensure on-the-spot decision-making at board meetings or even otherwise and together with civilian directors who are veterans in the technical and financial fields, he added.
“In this rehabilitation process, every aspect of this project stands as a model for productivity and efficiency for others to learn from,” he said.
Director of Ranaviru Apparels Rtd Lt Col Upali Gajanayake, formerly Deputy Chairman of Tri Star Apparels, told the Business Times that although disabled soldiers are paid their salaries, many are frustrated and depressed as they have no occupation and that is why they have decided to establish the garment factory to tailor the uniforms and also create gainful employment for disabled soldiers.
Almost all the workers have been provided accommodation facilities at the Ranaviru apparel complex. Some of them come to work from nearby villages traveling in their own three wheelers.
The concept and idea of the project was mooted by Brigadier H.I.K. Fernando together with Gamini Wickramanayake (then Major) and Capt. Mahesh Kumar when they were staff officers of the Directorate of Rehabilitation, he added.
Tristar Apparels assisted the army in setting up the factory and training for the first batch of disabled soldiers, he said.
At present all the employees are fully trained and they can undertake any type of apparel order as the factory is fully equipped with modern high tech machinery, he added.
Miss Yohini Thevathasan – Director, Sri Lanka Army Board of Management for Ranaviru Apparel noted that their management style is such that the needs of employees are regularly studied and affording welfare facilities to disabled soldiers is of paramount importance.
As per the army’s management style even minute problems of soldiers are discussed at the frequently held Board of Management meetings chaired by the Chief of Staff.
The culture of having free flow of lateral and vertical information through the chain of command facilitated efficient management.
The Chief of staff frequently visits the project and boosts the morale of the staff, she said.
Factory Manager Lt. Col. Amila Wasage and Production Manager Upul Ratnayake explained the production process at the factory.
Several assembly lines were operational at the factory. Two lines handled shirts while the other two handled trousers.
Each line is staffed by a Supervisor, Quality Controller, Machine Operators, Bottle Iron Operators and helpers.
Most of the machine operators were seen to be amputees. At present, the Ranaviru Apparels at Yakkala produces around 1000 uniform sets per day and expects to go into other areas of production.
In addition, the factory is producing folding mattresses to the army.
It has also entered the track kit production process, following increased demands of regiments, the two officers said.
A well-equipped library promotes those working at Ranaviru Apparels to enhance their knowledge and also study.
In-house training programmes are held for the soldiers and even, their families on various topics of interest. This includes ways of economizing and income generation which are always discussed and implemented, they added.
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