Setup a Carpet Manufacturing Plant

Project to setup a Carpet Manufacturing plant at Riviera Home Furnishing Pvt. Ltd., Panipat, Haryana.

June 2012, I was called from Riviera HR for a personal meeting about a new opportunity. That time I was working with Brintons Carpets (World leading company of Axminster Carpet Manufacturing) and I was happy with my Job. Hence, I was ignored that call from Riviera Company and tried to delay that meeting to re-think about that opportunity.

Lastly I went to Panipat and met Rivera’s CMD. Somehow I agreed to take this project and opportunity and joined Riviera on 30^th Aug 2012. I was the single person in my team and for that project. Hence, I got a big challenge to make a team for an implement of this project. This is because, the construction work was about to complete of the weaving shed and Shipment was expected to arrive at site probably by end of October 2012.

During those days, I spent most of the time finding a suitable team mates and planning a machine layout. Finally, I have selected three team mates from different background. Kewal Singh is an expert in machine tuning and weaving. Laval Singh is an expert in weaving preparatory and Anand Gautam was the union leader and handled tough workers and management staff. So, I have team leaders from different background to start this work. Also, I have selected 7 fitters from different background.

We were done all the cleaning and marking on floor for machine setup and waiting for a container which was shipped from UK. Daily we were expecting a container and spending time for proper marking on floor. Those days were little difficult for me to keep my team busy.

Finally 1^st container arrived at site. We were so excited to see the loom conditions. I was arranges, Forklift, Cranes, Heavy Labors and required man & materials for unloading the machines from container. Anand was taken a lead to unload the materials from containers. Unloading of machine was very risky and need accuracy. This is because, the entire machine are made up of Cast Iron. Finally entire team win and all the machines were unloaded safely, except one Loom. Minor damage happen during keeping the machine in plant and that was repaired after welding.

Next task was to put all the machines at exact place and clean the same. Roughly 2 – 3 weeks took to clean all the machines. Parallel to this task we are getting few more machines from Belgium and USA i.e. Van De Wiele, Construma & Tufting. Once Pradeep Pathania joined our team, I get breathing time. This is because, he is handling all material management and admin related task.

I and team have started errection work. By January 2013 we have erected mostly all the Looms. Next task was the creel & tubing errection and commissioning of Looms. We have started commissioning work and completed commissioning of 2 Narrow Looms, one 2 Mtr Axminster and 2 Van De Wiele Loom by mid of February 2013. Manish Mane from Brintons has joined our team who is having very rich experience of Axminster Looms. After joining of Manish, commissioning work were become faster and accurate. Finally, we have started production on Van De Wiele by mid of May. Also, we have completed Quality sample production of Axminster Loom by April 2013.

Right now, our 2 Axminster Looms are almost ready for production. 2 Van de Wiele looms are doing production work, Wire Wilton and Loop pile construma have started producing samples and 3 Coble Tufting machines have started producing samples. Right now the entire team size is 65.

During these periods, I use to wake up at 5:00 am and pick up most of the mates from their home and present at site by 7:00 am. Apart from this, we use to do party mostly all the days. Afgani from Malhotra (Shop) is become very famous among our self. And Pradeep is promoting Afgani.

We reach here, only because of team efforts. Otherwise this project was become a night mare for me.

Team work is a key of success.