ROLE OF FDDI IN FOOTWEAR SECTOR

ROLE OF FDDI IN FOOTWEAR SECTOR

FDDI is popularly known as Footwear Design & Development Institute. FDDI was set up by the Ministry of Commerce and Industry, Government of India in the year 1986 with an objective to develop professional Human resources within the country by imparting appropriate knowledge and skills to promote growth and to provide one stop solution to Footwear and Leather allied industry in the country.

Before starting the role of FDDI, firstly we will have a glance look on Indian Footwear Industry and its growth . India is the second largest producer of footwear after china. India’s export of footwear touched US $ 2531.04 million in 2013-14, accounting for a share of 41.14% in India’s total export from the leather sector of US $ 4996.91million. The Indian footwear sector is the ‘growth engine’ of the Indian Leather Industry.

Value in US$ Mn

India’s export of footwear has increased from US$ 1507.59 million in 2009-10 to US$ 2531.04 million in 2013-14, growing at a CAGR of 13.82% in the last five years ending 2013-14.

Export of different categories of Footwear holds a major share of about 43% in India’s total leather & leather Products exports with an export value of US$ 2531.04mn.                                                                                                                                                                                     

India is the only major source for supplying medium and low-priced footwear. Moreover, most of the global footwear manufacturers, particularly European manufacturers who were sourcing from China, have now turned to India. Nike, Adidas and Puma are some of the footwear majors are expected to route parts of their production and purchase out from China to India. Reputed global brands like Nunn Bush, Stacy Adams, Gabor, Clarks, Reebok, Hasley, Salamander and Colehaan are manufactured under license in India. US Retail giant Wal-Mart has also begun sourcing footwear from India like that many global retail chains seeking quality products at competitive prices are actively sourcing footwear from India.                                                                             

India has emerged in recent years as a relatively sophisticated low to medium cost supplier to world markets. The Footwear industry has potential to provide employment across all sections of the economy Industry estimates of employment potential 5 lakh jobs in next 3 years.

Mr.Puran Dawar, President of Agra Footwear Exporter and Manufactures Chamber (AFMEC) said that the target was to 'Make in India with Zero Defect and Zero Effect', which means that the quality of footwear produced in Agra should be above all standards, while its effect on the environment should be minimum, to the point of being Zero. FDDI Contribution in Central Government Make in India can be seen            on.                                                                   http://www.makeinindia.com/sector/leather

Footwear and leather sector industries are the largest industry in term of generating employment and there is huge opportunity for the youth to establish own factories, job work, production workshops, design studios, consultancy services etc.

The Indian shoe industry, including both the organized and the unorganized sector, the most of footwear industry is unorganized because they following traditional methods since the inception there is Lack of professional and educated man power in the industry, using manual methods of production and techniques, lack of R&D and innovative technique etc. FDDI contribute a lot towards the up gradation of footwear industries. With the objective to stream line the footwear industry by providing technocrat and skilled man power for the upliftment of the industry to compete the market at international level.

Dedicatedly, FDDI transform the footwear industry from unorganized to organized way, by providing highly educated footwear professionals, handling the day to day working of the industry from designing to production and up to the level of final packaging of shoes. It is the best example that most of the footwear companies’ top level officers, Presidents, MD, Directors are the FDDI alumni’s.

FDDI CONTRIBUTION FOR UPGRADATION OF FOOTWEAR SECTOR.

1.     INTERNATIONAL TESTING CENTRE (ITC)

 FDDI International Testing Center is a state-of-the-art facility established under German collaboration with the PFI Germany and with Bally, Switzerland. The center specializes in testing of leather products, footwear, footwear components, textile products & miscellaneous articles made up of plastics. In fact, it is the first facility of its own kind in whole of Asia to receive the coveted international accreditation from the Deutsche Germany for ISO 17025. ITC’s services represent an unmatched blend combining expertise with contemporary technology and modern equipment. Besides, it also possesses the flexibility to address a company’s unique individual requirement. ITC functioning in both of FDDI center Noida and Chennai.

 Accreditations:-

Ø  The International Testing Center is the only laboratory in India which has been ISO 17025 certified by Deutsche Akkreditierungsstelle DAkkS of Germany.

Ø  Our labs is also ISO 9001 & ISO 14001 certified

Ø  The International Testing Center, ITC FDDI, is accredited by SATRA.

Ø  Over and above our labs are recognized by various organizations and institutions.

The above accreditations underline our commitment in providing world-class service to our customers in India and abroad so that they can compete globally and sustain their growth and potential.

INDUSTRY NEED:-

 The International Testing Center offers a comprehensive range of physical and chemical tests on a variety of materials and products. It has a full complement of state of art testing equipment; all calibrated to the most demanding industry standards. The tests at the laboratories are conducted as per various standards depending on the customer’s requirement. Presently, the following materials and products are covered.

Ø  Leather for Footwear & Garments

Ø  Textile and Fabrics

Ø  Complete Footwear, Components & Allied Materials

Ø  Automobile (Parts & Accessories)

Ø  Ageing and Weathering Tests

Ø  Banned Chemicals including Disperse Dyes

2.      SKILL DEVELOPMENT PROGRAMME

One of the Biggest achievement of FDDI that till 30th November 2015, FDDI has trained 3,13,465 trainees & placed 2,52,335 candidates in various Footwear Industries across the country under PLSDP Programme. It is the huge figure of employment given after training in specified field by any Organization. Its show the opportunities in footwear sectors being provided by FDDI.

The Programme is designed for 06 Weeks (Incl. Classroom & Factory internship) and with objective to translate a fresh / unemployed/ unskilled candidate to a Semi- Skilled Operator, ready for Wage Employment in Footwear/ Garment/ Allied industry, where operation on stitching machines is majority performed. Alternately, he/She may also have access to precise Technical education for his/her Self-Employment (Entrepreneurship).The Programme is to run free of Cost to trainee and any Person aged 18-30 years, preferably unemployed and from EWS can apply.

During the Programme free Training Kits, Study book, ID card, Stationary etc. is provided to student. Free refreshment/ snacks are provided once a day, to each participant, for whole Programme. On successful completion of the Programme, a Certificate shall be awarded jointly by FDDI- SSE authority and trainee to be placed in relevant Industry for employment opportunity.

In continuation to 11th Five Year Plan Footwear Design & Development Institute (FDDI) is implementing “Placement Linked Skill Development Programme (PLSDP) under the XIIth Five Year Plan of the Government of India in association with Department for Industrial Policy and Promotion (DIPP).The training programmes were conducted at various operators training centers such as Agra, Kanpur, Fursatganj, Bareilly, Delhi/NCR, Bahadurgarh, Kolkata, Ranipet, Maharastra & Bihar. To provide the training programme at doorstep of unemployed youth, various sub-centers were also established in the remote areas &, the training programmes were also carried out at the places provided by the factory owners, shoe organizations & other onsite locations. The areas of specialization of the training were mainly Cutting, Closing, Lasting and Finishing The course curriculum of this training is as follows: Cutting- Tin Pattern Making, Hand Cutting, Machine Cutting, Leather Inspection, Quality region of Hide and Side leather, Part of shoe, how to cut leather with quality- leather manipulation. Closing- Types of Needles, Threads, Relation between thread and needle, Different types of stitching machines, Different types of stitching operations (seams), Upper making & minor machine maintenance. INDUSTRY NEED:- The requirement of the training program has been improved in quality and the increase in productivity with use of modern techniques, tool standardization, designs and methods. The efforts to increase the availability of skilled manpower is of crucial significance as the growing skill manpower shortage is posing constraints for utilizing the full growth potential of the Indian Leather industry and the FDDI is leaving no stone unturned as far as the growth of the footwear and leather products industries industry is concerned. FDDI has already provided trained, manpower to renowned footwear companies such as M/s. Prime Shoes Chennai, M/s. N. M. Zackriah & Company, Ambur, M/s. Dawar Shoes Agra, M/S. Arvind Footwear Kanpur, M/s. Rohit Surftrants Kanpur, M/s. SSIPL Ltd., Sonepat, M/s. Super House, Unnao, M/s. Tata International, Dewas, M/s. Oscar Leather Mohali, etc. The requirement to train the workers from other companies is also coming.

3.      RESOURCE CENTER

FDDI's Resource-cum-Information Publication Centre (RCIP) brings you an exhaustive and unparalleled resource and information base. The Centre provides timely, policy-relevant information and decision support to government agencies, non-profit organizations, and the industry across the country and around the globally.

The Centre publishes a series of specialized manuals called “Swayam Siddha Manuals” (the art of self-learning), which deals on different aspects of leather & leather products manufacturing. These “Swayam Siddha Manuals” covers the entire aspects of manufacturing and is a tri-lingua book (Hindi, English & Tamil), made in a very lucid manner and is easily understood by the persons working at all the levels. These manuals are in module & covers safety, tools and so on with all basic needs of technical terms being used in manufacturing of leather & leather products.

INDUSTRY NEED:-

Swayam Siddha Manuals Books helps to understand the technical as well as the practical knowledge of footwear production operation with well given demonstration example and photos. Swayam siddha books and training material provide all the basic level knowledge which actually worker required. It helps to trained and imparts the basic knowledge of the footwear industry.

4.      PRODUCT DEVELOPMENT CENTER

The Product Development Center (PDC) creates a design data bank based on the latest fashion information, lasts, soles and leather. These designs are kept for display at FDDI premises so that the footwear industry can avail the latest fashion information. To make this facility more effective, FDDI’s PDC uses its most sophisticated software systems, such as,

Ø  2D & 3D CAD Systems.

Ø  CAM Systems, NC Machining.

Ø  Surface Modeling Systems, to provide end-to-end solutions.

PDC develops the designs for the industry as per their specific requirement keeping in mind the targeted market segment. The services of our PDC are not only availed by Indian industries that includes, major export houses but from various companies overseas from U.K., Sri Lanka, Pakistan, Nepal, South Africa, Bangladesh, etc.

INDUSTRY NEED:-

Progressive looking exporters who desire to invest in design range building may be supported to set up design studio in their factories. Design studios in institutions that need to complement their activities and add value to the services rendered by them to the industry or for design research may be supported as well:-Studios run by free-lance designers may be given opportunities at Indian expositions at subsidized cost to enable them to reach out to the industry through design alleys.

5.      International Design Studio

The IDS (International Design Studio) develops its own design collection (Last shape, concept on design, material, color and accessories along with the prototype samples) for the industry on demand and as the routine exercise of FDDI Student to know the current trends of conceptual designing. The Design Center also provides its customers with new original and exclusive sketches and design development on request order meet the international standard requirement. Design Center also develops its own design collection for Display at various fairs and exhibitions, for that all necessary information sourced by our Designers. The information are collected from study of International trend Magazines, Designers, Fair visits, Market research and traveling by our Designers from time to time In case the customer provides the sketches, photographs or shoes in that case design center provide the pattern cutting services. Regular workshops of shoe designing are being conducted time to time by the renowned shoes designer from Italy.

INDUSTRY NEED:-

There is continuous need to focus on design and pattern development for leather products and institutional support is this aspect is necessary. Institutions may like to train/retrain their personnel with exposure to international methods. International designing workshop help Students to get interacted with the latest trends and designing concept for the overall development of future shoe designer. The same is applicable for the candidates from the industry as well.

6.      CAD / CAM LABS

FDDI’s PDC is well equipped with modern software for last modelling. The software used are one of the most advanced software in the field of last modelling and uses the latest techniques for generating the last data from the actual foot scanning. The accuracy can be rated up to 100 per cent. Besides using this software for the style last designing for the domestic as well as export market, this will prove a blessing for the people who are having foot deformities and are not able to get a proper pair of shoes which can fit their feet.

FDDI provides the grading services to the industry through its well-equipped CAD Center. Besides the Indian market FDDI is providing its grading services to various other overseas companies based in Sri Lanka, Bangladesh, Pakistan, Nepal etc.

INDUSTRY NEED:-

We need to popularize the use of 3D CAD system for the last digitizing and modeling, conceptual designing and sole design and manufacture. The design studios in institutions and factories need to be equipped with the latest cad system in addition to other automated peripherals like the die-less cutter to directly cut the leather and punch cutter for cutting materials of higher thickness. 

7.      SAMPLE DEVELOPMENT

The Design Studio is backed by the services of well-equipped sample room. Designs developed by the design studio are tested for its fittings, aesthetic taste, proportions, leather qualities and other costing aspects and finally handed over to the customers. The sample room also provides sampling services to those entrepreneurs who do not have in-house facilities for sample developments. As their part of study students are engaged to develop various range of footwear like open footwear, sports and casual footwear etc. and being displayed time to time to show case their creativity and talent. The selected designs are being awarded by accolade in different segments.

INDUSTRY NEED:-

We need upgrade the sample development cells and employ trained technicians to use world class equipment to translate them into products comparable with the best worldwide. The same development cell should be stocked with samples of leather, fabrics lasts soles heels and other components in accordance with the latest fashion trends and produce samples that can be exhibited at international fora. 

8.      PROTOTYPE DEVELOPMENT

Development of Rapid Prototyping technologies, 3 D printing and advances in CAD and design methodologies led to a revolution in product development strategies. Today, India is second to none when it comes to developing innovative, new products. In this success, advanced CAD and 3D printing / Rapid Prototype are playing an increasingly important role.

FDDI has the distinction of introducing the latest 3D printing technologies in the service of Indian footwear industry. This is first installation of its kind in India. It can produce a model within 3 to 4 hours with high accuracy and smooth finish for which other Rapid Prototyping machines may take 3 to 4 days for printing.

INDUSTRY NEED:-

The question may arises where will it improve the business and how? The answer lies in these four semi sentences.

a.      To prove the product

b.      To sell the product

c.       To make the product

d.      To reduce the cost and lead-time

9.      Last Modeling

The foot scanner scans the foot up to the leg height in all the 3 dimensions and thus gives a proper fit and comfort for the user of the shoes developed on the so developed lasts. The last can be generated from the scanned cloud data and milled out on a tabletop milling machine. The process is too fast and cut the lead-time down as well as cost effective.

INDUSTRY NEED:-

Last modeling develop the new concept to work with innovative ideas and help the manufacture to reduce the cost of making the shoes with well satisfy customers and with   less time consuming process.

10.  Sole Designing & Mould Making

Sole designing and sole mould designing, till recently was non-existent in India. 20 to 25 per cent of the total foreign exchange earnings from the footwear industry were plaguing back to the suppliers of the sole and sole mould. FDDI has taken a big leap in the direction and installed the most sophisticated and is one of the most advanced software for sole and sole mould designing. These software systems takes the care of surface modelling of the sole and hands over the data to a Milling system, which can use the surface modelling data for the CNC use and thus complete the sole mould designing.

INDUSTRY NEED:-

By this important step of FDDI towards making sole designing and mould making facility it’s not only stops the dependency of Indian manufacturer over foreign countries, but also help to earn more profit with high satisfaction.

11.  FDDI DEVELOP ANTI MINE SHOE FOR INDIAN ARMY

Footwear Design and Development Institute (FDDI), Noida, in association with Defense Material Store Research Development Establishment (DMSRDE) has developed an 'Anti-Mine Blast Shoes' for the Armed forces of the country. ''The Shoe mitigates the shock energy of mine blast to restrict the sustainable injuries level to the minimum. These shoes would prove to be real life-savers for the troops posted in terrorism affected areas,'' FDDI said in a statement.

As per the directions of the Ministry of Defence, the product is an outcome of two years long intense efforts of Research and Development teams of both the organization.

Explaining about the technical specifications of the shoes Mr VB Parvertikar, Technical Director, FDDI said,''The 'Anti-Mine Blast' shoe mitigates the landmine blast shock energy of 40 thousand per cm square to 160 per cm square. The shoe has an insert block which turns into powder to absorb about 95 per cent of the shock energy caused by landmine blast. It thus, provides a protection shield to the legs of the soldiers to sustain only minor injuries.'' Terminal Ballistic Research Laboratory has also tested the shoes successful and now it has been sent to the Army for test by the soldiers. ''Developed by intense research efforts of two years the anti-mine boot weighs 35 gm,''

12.  CONSULTANCY SERVICES

FDDI also offer the consultancy services for the purpose to provide one stop solutions to all problem faced by footwear sectors. From factory set up, layout making, designing issues, troubleshooting, cost reduction and productivity & quality improvement, sourcing, documentation and software development.FDDI has helped lot of industries for transfer of latest technology and improvement of quality and productivity.

FDDI have international project in many countries like Ethiopia, South Africa,Kenya, Botswana, Nigeria, Vietnam, Srilanka, Bangladesh.

INDUSTRY NEED:-

Consultancy helped the indian exporters to improve the competitiveness in the international market.The services are given as per the requirement of the individual industry. The key areas of consultancy are following:-

Ø  TROUBLESHOOTING

Ø  Productivity

Ø  Quality improvement

Ø  Cost reduction

Ø  Material saving

Ø  Process improvement

Ø  Skill upgradation

Ø  Quality system

Pradeep Kumar Shukla

Associate Faculty FDDI