A PROJECT REPORT ON

“AN ANALYSIS OF MANUFACTURINGS & LOGISTICS MANAGEMENT IN

BY

PRAVIN PANSURIYA

SUBMITTED FOR THE PARTIAL FULLFILMENT OF

POST GRADUATE DIPLOMA IN

MATERIALS & LOGISTICS MANAGEMENT

FROM MATRIX BUSINESS SCHOOL-PUNE

YEAR: 2009-2010

MATRIX BUSINESS SCHOOL

S. NO. 9/1/5 & 9/2/4, OFF WESTERLY BYPASS ROAD,

AMBEGAON (BK.)

PUNE-411041

1
 “AN ANALYSIS OF MANUFACTURINGS & LOGISTICS MANAGEMENT

IN

BHILOSA INDUSTRIES PVT LTD

UNDER THE GUIDANCE OF: SUBMITTED BY:

HETESHBHAI CHOVATIA PRAVIN PANSURIYA

Production Manager Matrix Business School

BHILOSA INDUSTRIES PVT LTD Pune-41

Rakholi, Silvassa (UT) Maharatra

India

MATRIX BUSINESS SCHOOL

S.No.9/1/5&9/2/4, Off Westernly Bypass Road, Ambegaon (BK),

Pune.41
2
 DECLARATION

I, PRAVIN PANSURIYA hereby declare that this project report is the record of authentic
work carried out by me during the period has not been submitted earlier to any university or
institute for the award of any degree/diploma etc.

Name of the Student: PRAVIN PANSURIYA

Date:

3
 ACKNOWLEDGEMENT

This project has been an honest and dedicated attempt to make the analysis on production
management material as authentic as it could. And I earnestly hope that it provides useful and
workable information and knowledge to any person reading it.

During this period, I had the pleasure of working closely with accomplished organization people
who shared with me their experience and helped me in completion of my research.

I express my sincere thanks to my project guides and my institute faculty for guiding me.

Lastly I am grateful to my parents who been my mentors and motivators. I am also thankful to all
my batch mates who have been directly or indirectly involved in successful completion of this
project.

4
 CERTIFICATE

This is to certify that the project titled “AN ANALYSIS OF MANUFACTURINGS &
LOGISTICS MANAGEMENT IN BHILOSA INDUSTRIES PVT LTD” is a bonafide work
carried out by PRAVIN PANSURIYA. A student of post graduate diploma in materials and
logistics management course at Matrix Business School, Pune for fulfillment of PGDMLM
course of university of Pune. He has worked under our guidance and direction. His work is found
satisfactory and complete in all respects.

Director Project Guide

Dr. J.N. POL Prof. Shantanu Jahagidar

Date : Date :

Place: Pune Place: Pune

5
6
TABLE OF CONTENTS
Chapter Contents Page No:
No:

1. INTRODUCTION AND THEORITICAL

BACKGROUND OF THE STUDY
A) Objective of Study 9
B) Founders of Company 10
C) Board of Directors 10
D) Yarn Manufacturing Process 13
E) Indian Yarn Market 24
2. PROFILE OF THE COMPANY
A) Industry Profile 33
B) Company Profile and History 34
C) Location of Offices 36
D)Product Profile 37
E)Plant Layout of Company 43
3. Machinery Details 46
4. Manpower 49
5. Role of Raw Material, Production Process and Finish 51
Good
6. Quality Control 59
7. Role of IT in Warehousing and Packing 61
8. Materials handling and packaging systems 62
9. Warehousing and Transportation 66
10. Analysis and Interpretation of Data 68
11. Finding and Conclusions 69
12. Bibliography 70

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EXECUTIVE SUMMARY

The aim of this project was to study in detail the production management & logistics of Bhilosa
Industries Pvt Ltd and to collect details regarding it. This project deals with a detailed analysis
what is the production strategy of the Bhilosa Company and its effectiveness in the yarn market.
The data collected gives information on various aspects of production & logistics, as also about
product of the company.

Bhilosa industries Pvt Ltd is one of golden hand of Bhilosa Groups Company.

It has established by Ramesh Jain in Silvassa since 1989 with capital USD 5000000-10000000.

Bhilosa industries is manufacturing textured yarn , POY (partially oriented yarn),

CP (continun polymers). As also spinning, weaving, garments & exporting all product in the
global market.

Bhilosa Company is one of the largest yarn production companies in the textile market

There are five plant of various activities at Silvassa (UT) as like Spinning, Texturing, Weaving,
Garment.

Bhilosa produces POY & FDY yarn as per market demand & customer satisfaction with quality
management.

8
 CHAPTER 1:

INTRODUCTION:

Bhilosa started as a small textile industry in 1989 from Piparia plant founded by Ramesh Tejrajji
Jain. At that time, he has started tow texturing machine, TFO (Two for One) Twist machine at
Piparia with looms units at Bhivandi. In short time, Bhilosa has expanded their business with
establishing Two new texturing plant at 17/1/4 & 14/1/1-2, Rakholi , one of the having 36
texturing machine and other is having 10 texturing machine. After Bhilosa focus into POY plant
development and started developing customized row materials for their texturing plant as well as
customers. This expanded their yarn business and subsequently started new plant with chip plant,
POY plant, texturing plant all are one roof. Ramesh Jain has two sons Kumar Jain who is
managing director & head officer of marketing department & Sandeep Jain who is managing
director & head officer of factory department.

Bhilosa, a name associated with some of the big business houses, is one of India’s largest
manufacturing company of Polyester Textured Yarn. With more than a hundred years of tradition
in the textile industry, Bhilosa group today manufactures a wide range of polyester texturised
yarn for the domestic and export markets. Backed with a tradition in textile trade spanning over a
hundred years, Chairman Mr. Ramesh Jain set up the Bhilosa Group in 1989 with an initial
capacity of 580 Metric Tonnes per annum, now the capacity has gone to 50, 000 Metric Tonnes
per annum and expected to grow at faster rate. Since then the Group has been steadily advancing
by building up on its volumes and enhancing the production capacity every two years. Today it
has marked out its position of being one of the largest manufacturers of Texturised yarn in India,
and it enjoys a strong national as well as international presence.

OBJECTIVE OF STUDY:

Management Objective

To fuel initiative and foster activity by allowing individuals freedom of action and innovation in
attaining defined objectives.

To understand process of manufacturing & logistics management apply in real industries

9
Core Values

♦ It is uphold the dignity of individual.

♦ It is honour all commitments.

♦ It is committed to quality, Innovation and growth in every endeavour.

♦ It is responsible Corporate Citizens.

BOARD OF DIRECTOR :

Founders of Company

Ramesh Jain is good entrepreneur of textile market. He has founded Bhilosa Groups Company
at 1989. Bhilosa Industries Pvt. Ltd is aspect of Bhilosa Groups Company which is
manufacturing of yarn as also raw materials of POY. Ramesh Jain is chairman & managing
director of Bhilosa Industries Pvt. Ltd.

Board of Directors

Ramesh Jain – CMD & founder

Kumar Jain - managing director & head of marketing department

Sandeep Jain – CEO & head of factory department

10
MANUFACTURING:

Manufacturing is the use of machines, tools and labor to make things for use or sale. The term
may refer to a range of human activity, from handicraft to high tech, but is most commonly
applied to industrial production, in which raw materials are transformed into finished goods on a
large scale. Such finished goods may be used for manufacturing other, more complex products,
such as household appliances or automobiles, or sold to wholesalers, who in turn sell them to
retailers, who then sell them to end users - the "consumers".

Manufacturing takes turns under all types of economic systems. In a free market economy,
manufacturing is usually directed toward the mass production of products for sale to consumers
at a profit. In a collectivist economy, manufacturing is more frequently directed by the state to
supply a centrally planned economy. In free market economies, manufacturing occurs under
some degree of government regulation.

MANUFACTURING MANAGEMENT

• Types of Manufacturing methods

Manufacturing

Intermitten Continuous
t

Project Jobbin Batch Mass-Flow Process

g

11
• Plant Layout

• Plant location

Planning & controlling

• Forecasting / demand forecasting

• Capacity planning

• Resource planning

• Just-In-Time (JIT)

• Scheduling

• Material Requirement Planning (MRP)

• Enterprise Resource Planning (ERP)

Typical modules in ERP –

1) Sales & Distribution

2) Production Planning

3) Logistics

4) Finance & Accounts

5) Operational Control

6) Purchase / Materials

7) Human Resources

• Plant facilities & layouts

• Quality control

12
MANUFACTURINGS PROCESS:

13
PET
Chips

To

POY

14
 POY

To

DTY

Textile manufacture is a major industry. It is based in the conversion of three types of fibre
into yarn, then fabric, then textiles. These are then fabricated into clothes or other
artifacts. Cotton remains the most important natural fibre so is treated in depth. There are
15
many variable processes available at the spinning and fabric-forming stages coupled with
the complexities of the finishing and colouration processes to the production of wide ranges
of products.

YARN MANUFACTURING PROFILE

Background

Yarn consists of several strands of material twisted together. Each strand is, in turn, made of
fibers, all shorter than the piece of yarn that they form. These short fibers are spun into longer
filaments to make the yarn. Long continuous strands may only require additional twisting to
make them into yarns. Sometimes they are put through an additional process called texturing.

The characteristics of spun yarn depend, in part, on the amount of twist given to the fibers during
spinning. A fairly high degree of twist produces strong yarn; a low twist produces softer, more
lustrous yarn; and a very tight twist produces crepe yarn. Yarns are also classified by their
number of parts. A single yarn is made from a group of filament or staple fibers twisted together.
Ply yarns are made by twisting two or more single yarns. Cord yarns are made by twisting
together two or more ply yarns.

Almost eight billion pounds (3.6 billion kg) of spun yarn was produced in the United States
during 1995, with 40% being produced in North Carolina alone. Over 50% of spun yarn is made
from cotton. Textured, crimped, or bulked yarn comprised one half of the total spun. Textured
yarn has higher volume due to physical, chemical, or heat treatments. Crimped yarn is made of
thermoplastic fibers of deformed shape. Bulked yarn is formed from fibers that are inherently
bulky and cannot be closely packed.

Yarn is used to make textiles using a variety of processes, including weaving, knitting, and
felting. Nearly four billion pounds (1.8 billion kg) of weaving yarn, three billion pounds (1.4 kg)
of machine knitting yarn, and one billion pounds (450 million kg) of carpet and rug yarn was
produced in the United States during in 1995. The U.S. textile industry employs over 600,000
workers and consumes around 16 billion pounds (7 billion kg) of mill fiber per year, with
industry profits estimated at $2.1 billion in 1996. Exports represent more than 11% of industry
sales, approaching $7 billion. The apparel industry employs another one million workers.

History

Natural fibers—cotton, flax, silk, and wool—represent the major fibers available to ancient
civilizations. The earliest known samples of yarn and fabric of any kind were found near
Robenhausen, Switzerland, where bundles of flax fibers and yarns and fragments of plain-weave
linen fabric, were estimated to be about 7,000 years old.

Cotton has also been cultivated and used to make fabrics for at least 7,000 years. It may have
existed in Egypt as early as 12,000 B.C. Fragments of cotton fabrics have been found by
archeologists in Mexico (from 3500 B.C. )., in India (3000 B.C. ), in Peru (2500 B.C. ), and in
16
the southwestern United States (500 B.C. ). Cotton did not achieve commercial importance in
Europe until after the colonization of the New World. Silk culture remained a specialty of the
Chinese from its beginnings (2600 B.C. ) until the sixth century, when silkworms were first
raised in the Byzantine Empire.

Synthetic fibers did not appear until much later. The first synthetic, rayon, made from cotton or
wood fibers, was developed in 1891, but not commercially produced until 1911. Almost a half a
century later, nylon was invented, followed by the various forms of polyester. Synthetic fibers
reduced the world demand for natural fibers and expanded applications.

Until about 1300, yarn was spun on the spindle and whorl. A spindle is a rounded stick with
tapered ends to which the fibers are attached and twisted; a whorl is a weight attached to the
spindle that acts as a flywheel to keep the spindle rotating. The fibers were pulled by hand from a
bundle of carded fibers tied to a stick called a distaff. In hand carding, fibers are placed between
two boards covered with leather, through which protrude fine wire hooks that catch the fibers as
one board is pulled gently across the other.

The spindle, which hangs from the fibers, twists the fibers as it rotates downward, and spins a
length of yarn as it pulls away from the fiber bundle. When the spindle reaches the floor, the
spinner winds the yarn around the spindle to secure it and then starts the process again. This is
continued until all of the fiber is spun or until the spindle is full.

A major improvement was the spinning wheel, invented in India between 500 and 1000 A.D. and
first used in Europe during the Middle Ages. A horizontally mounted spindle is connected to a
large, hand-driven wheel by a circular band. The distaff is mounted at one end of the spinning
wheel and the fiber is fed by hand to the spindle, which turns as the wheel turns. A component
called the flyer twists the thread just before it is wound on a bobbin. The spindle and bobbin are
attached to the wheel by separate parts, so that the bobbin turns more slowly than does the
spindle. Thus, thread can be twisted and wound at the same time. About 150 years later, the
Saxon wheel was introduced. Operated by a foot pedal, the Saxon wheel allowed both hands the
freedom to work the fibers.

A number of developments during the eighteenth century further mechanized the spinning
process. In 1733, the flying shuttle was invented by John Kay, followed by Hargreaves' spinning
jenny in 1766. The jenny featured a series of spindles set in a row, enabling one operator to
produce large quantities of yarn. Several years later Richard Arkwright patented the spinning
frame, a machine that used a series of rotating rollers to draw out the fibers. A decade later
Samule Cromptons' mule machine was invented, which could spin any type of yarn in one
continuous operation.

The ring frame was invented in 1828 by the American John Thorp and is still widely used today.
This system involves hundreds of spindles mounted vertically inside a metal ring. Many natural
fibers are now spun by the open-end system, where the fibers are drawn by air into a rapidly
rotating cup and pulled out on the other side as a finished yarn.

17
Raw Materials

About 15 different types of fibers are used to make yarn. These fibers fall into two categories,
natural and synthetic. Natural fibers are those that are obtained from a plant or an animal and are
mainly used in weaving textiles. The most abundant and commonly used plant fiber is cotton,
gathered from the cotton boil or seed pod when it is mature. In fact, cotton is the best-selling
fiber in America, outselling all synthetic fibers combined.

Fibers taken from the plant leaf or stern are generally used for rope. Other plant fibers include
acetate (made from wood pulp or cotton linters) and linen, made from flax, a vegetable fiber.
Animal fibers include wool, made from sheep hair, and mohair, made from angora goats and
rabbits. Silk is a protein extruded in long, continuous strands by the silkworm as it weaves its
cocoon.

Synthetic fibers are made by forcing a thick solution of polymerized chemicals through spinneret
nozzles and hardening the resulting filament in a chemical bath. These include acrylic, nylon,
polyester, polyolefin, rayon, spandex, and triacetate. Some of these fibers have similar
characteristics to the natural fibers without the shrinkage problems. Other fibers have special
properties for specific applications. For instance, spandex can be stretched over 500% without
breaking.

Fibers are shipped in bales, which are opened by hand or machine. The picker loosens and
separates the lumps of fiber and also cleans the fiber if necessary. The carding machine separates
the fibers and pulls them into somewhat parallel form. The thin web of fibers formed then passes
through a funnel-shaped device that produces a ropelike strand of parallel fibers. Rollers elongate
the strand, called a sliver, into a single more uniform strand that is given a small amount of twist
and fed into large cans.

18
The Manufacturing Process

There are three major spinning processes: cotton, worsted or long-staple, or wool. Synthetic
staple fibers can be made with any of these processes. Since more yarn is produced with the
cotton process than the other two, its manufacture is described below.

Preparing the fibers

• 1 Fibers are shipped in bales, which are opened by hand or machine. Natural fibers may
require cleaning, whereas synthetic fibers only require separating. The picker loosens and
separates the lumps of fiber and also cleans the fiber if necessary. Blending of different staple
fibers may be required for certain applications. Blending may be done during formation of
the lap, during carding, or during drawing out. Quantities of each fiber are measured
carefully and their proportions are consistently maintained.

Carding

• 2 The carding machine is set with hundreds of fine wires that separate the fibers and pull
them into somewhat parallel form. A thin web of fiber is formed, and as it moves along, it
passes through a funnel-shaped device that produces a ropelike strand of parallel fibers.
Blending can take place by joining laps of different fibers.

Combing

• 3 When a smoother, finer yarn is required, fibers are subjected to a further paralleling
method. A comblike device arranges fibers into parallel form, with short fibers falling out of
the strand.

Drawing out

• 4 After carding or combing, the fiber mass is referred to as the sliver. Several slivers are
combined before this process. A series of rollers rotating at different rates of speed elongate
the sliver into a single more uniform strand that is given a small amount of twist and fed into
large cans. Carded slivers are drawn twice after carding. Combed slivers are drawn once
before combing and twice more after combing.

Twisting

• 5 The sliver is fed through a machine called the roving frame, where the strands of fiber are
further elongated and given additional twist. These strands are called the roving.

Spinning

• 6 The predominant commercial systems of yarn formation are ring spinning and open-end
spinning. In ring spinning, the roving is fed from the spool through rollers. These rollers
elongate the roving, which passes through the eyelet, moving down

19
The sliver is fed through a machine called the roving frame, where the strands of fiber are further
elongated and given additional twist. The predominant commercial systems of yarn formation
are ring spinning and open-end spinning. Open-end spinning omits the roving step.

and through the traveler. The traveler moves freely around the stationary ring at 4,000 to 12,000
revolutions per minute. The spindle turns the bobbin at a constant speed. This turning of the
bobbin and the movement of the traveler twists and winds the yarn in one operation.

• 7 Open-end spinning omits the roving step. Instead, a sliver of fibers is fed into the spinner
by a stream of air. The sliver is delivered to a rotary beater that separates the fibers into a thin
stream that is carried into the rotor by a current of air through a tube or duct and is deposited
in a V-shaped groove along the sides of the rotor. As the rotor turns, twist is produced. A
constant stream of new fibers enters the rotor, is distributed in the groove, and is removed at
the end of the formed yarn.

Quality Control

Automation has made achieving quality easier, with electronics controlling operations,
temperatures, speeds, twists, and efficiency. The American Society for Testing of Materials has
also established standardized methods for determining such properties as drawforce, bulk, and
shrinkage.
20
The Future

Spinning systems and yarn manufacturing machinery will continue to become more automated
and will be integrated as part of a manufacturing unit rather than as a separate process. Spinning
machines have already been developed that combine carding and drawing functions. Production
rates will increase by orders of magnitude as machines become available with even more
spindles. Robot-controlled equipment will become standard.

Domestic yarn producers will continue to be threatened by competition from Asian countries, as
these countries continue to buy the latest textile machinery technology. Higher domestic material
prices will not help, since the cost of the raw material can represent up to 73% of the total cost of
producing the yarn. U.S. yarn producers will continue to form alliances with their customers and
customers' customers to remain competitive. The textile industry is also forming unique
partnerships. The American Textile Partnership is a collaborative research and development
program among industry, government, and academia aimed at strengthening the competitiveness
of the U.S. industry.

Another continuing challenge for the industry will be compliance with stricter environmental
regulations. Recycling is already an issue and processes are under development to manufacture
yarn from scrap material, including denim. Yarn producers will have to incorporate pollution
prevention measures to meet the air and water quality restrictions. Equipment manufactures will
continue to play an important role in this endeavor.

Genetic engineering will become more widely used for developing fibers with unique properties.
Researchers have developed genetically-altered cotton plants, whose fibers are especially good at
retaining warmth. Each fiber is a blend of normal cotton and small amounts of a natural plastic
called polyhydroxybutyrate. It is predicted that dye-binding properties and greater stability will
be possible with new fibers in the next generation.

New synthetic fibers will also be developed that combine the best qualities of two different
polymers. Some of these fibers will be produced through a chemical process, whereas others will
be generated biologically by using yeast, bacteria, or fungi.

The Indian textile industry is one the largest and oldest sectors in the country and among the
most important in the economy in terms of output, investment and employment. The sector
employs nearly 35 million people and after agriculture, is the second-highest employer in the
country. Its importance is underlined by the fact that it accounts for around 4% of Gross
Domestic Product, 14% of industrial production, 9% of excise collections, 18% of employment
in the industrial sector, and 16% of the country’s total exports earnings. With direct linkages to
the rural economy and the agriculture sector, it has been estimated that one of every six
households in the country depends on this sector, either directly or indirectly, for its livelihood.

A strong raw material production base, a vast pool of skilled and unskilled personnel, cheap
labour, good export potential and low import content are some of the salient features of the
Indian textile industry. This is a traditional, robust, well-established industry, enjoying
considerable demand in the domestic as well as global markets.

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 INDIAN YARN MARKET

The global textile and clothing industry is estimated to be worth about US$ 4,395 bn and
currently global trade in textiles and clothing stands at around US$ 360 bn. The US market is the
largest, estimated to be growing at 5% per year, and in combination with the EU nations,
accounts for 64% of clothing consumption.

The Indian textile industry is valued at US$ 36 bn with exports totalling US$ 17 bn in 2005-
2006. At the global level, India’s textile exports account for just 4.72% of global textile and
clothing exports. The export basket includes a wide range of items including cotton yarn and
fabrics, man-made yarn and fabrics, wool and silk fabrics, made-ups and a variety of garments.
Quota constraints and shortcomings in producing value-added fabrics and garments and the
absence of contemporary design facilities are some of the challenges that have impacted textile
exports from India.

India’s presence in the international market is significant in the areas of fabrics and yarn.

• India is the largest exporter of yarn in the international market and has a share of 25% in
world cotton yarn exports

• India accounts for 12% of the world’s production of textile fibres and yarn

• In terms of spindleage, the Indian textile industry is ranked second, after China, and accounts
for 23% of the world’s spindle capacity

• Around 6% of global rotor capacity is in India

• The country has the highest loom capacity, including handlooms, with a share of 61% in
world loomage.

India’s Textile Industry Structure

Cotton textiles continue to form the predominant base of the Indian textile industry, though other
types of fabric have gained share in recent years. In 1995-96, the share of cotton and manmade
fabric was 60% and 27% respectively. More recently, cotton fabrics accounted for 46% of the
total fabric produced in 2005-06, while man-made fibres held a share of 41%. This represents a
clear shift in consumer preferences towards man-made fabric.

22
The Textile and Apparel supply chain

The fibre and yarn-specific configuration of the textile industry includes almost all types of
textile fibres, encompassing natural fibres such as cotton, jute, silk and wool; synthetic / man-
made fibres such as polyester, viscose, nylon, acrylic and polypropylene (PP) as well as multiple
blends of such fibres and filament yarns such as partially oriented yarn (POY). The type of yarn
used is dictated by the end product being manufactured.

The Man-made textile industry comprises fibre and filament yarn manufacturing units of
cellulosic and non-cellulosic origin. The cellulosic fibre/yarn industry is under the administrative
control of the Ministry of Textiles, while the non-cellulosic industry is under the administrative
control of the Ministry of Chemicals and Fertilisers.

It is well-established that India possesses a natural advantage in terms of raw material

availability. India is the largest producer of jute, the second-largest producer of silk, the third-
largest producer of cotton and cellulosic fibre/yarn and fifth-largest producer of synthetic
fibres/yarn.

The industry structure is fully vertically integrated across the value chain, extending from fibre
to fabric to garments. At the same time, it is a highly fragmented sector, and comprises small-
scale, non-integrated spinning, weaving, finishing, and apparel-making enterprises. The
unorganised sector forms the bulk of the industry, comprising handlooms, powerlooms, hosiery
and knitting, and also readymade garments, khadi and carpet manufacturing units. The organised
mill sector consists of spinning mills involved only in spinning activities and composite mills
where spinning, weaving and processing activities are carried out under a single roof.

As in January 2006, there were 1779 cotton/man-made fibre textile mills in the organised sector,
with an installed capacity of 34.1 million spindles and 395,000 rotors. Of these, 218 were
composite mills which accounted for just 3% of total fabric production, with 97% of fabric
production happening in the unorganised segment. Cloth production in the mill sector has fallen
from 1,714 million sq mtrs in 1999-2000 to a projected 1,493 million sq mtrs in 2005-06,
declining at a rate of 2% per annum. As a result, the number of sick units in the organised
segment has also been growing rapidly.

The competitiveness of composite mills has declined in comparison to the powerlooms in the
decentralised segment. Policy restrictions relating to labour laws and the fiscal advantages
enjoyed by the handloom and powerloom sectors have been identified as two of the major
constraints responsible for the declining scenario of the mill sector.

Nonetheless, overall cloth production in the country has been growing at 3.5% per annum since
2000, with growth driven largely by the powerloom sector. Being the largest manufacturer of
fabric in the country, the powerloom sector produces a wide variety of cloth, both grey as well as
processed. According to the Ministry of Textiles, there are 1.923 mn powerlooms in the country
distributed over 430,000 units. The sector accounts for 63% of the total cloth production in the
country and provides employment to 4.815 mn people.

23
The handloom sector is the second-highest employer in the country after agriculture. The sector
accounts for 13% of the total cloth produced in the country, not including wool, silk and
handspun yarn. The production of handloom fabrics had gone up to 4629 mn sq mtrs in 2005,
from 500 mn sq mtrs in the 1950s, representing an annual growth of around 4%. The sector is
weighed down by several problems such as obsolete technology, unorganised production
systems, low The Man-made textile industry comprises fibre and filament yarn manufacturing
units of cellulosic and non-cellulosic origin. The cellulosic fibre/yarn industry is under the
administrative control of the Ministry of Textiles, while the non-cellulosic industry is under the
administrative control of the Ministry of Chemicals and Fertilisers. XV productivity, weak
marketing links, overall stagnation in demand and competition from the powerloom and mill
sectors.

Knitting and hosiery units account for around 17% of fabric production in the country.
According to data available for the year 2000, India had about 6,000 knitting units registered as
producers or exporters and most of these units were registered as small-scale units.

Trends in Production

Yarn and fabric production has been growing annually at 1.9% and 2.7% respectively, since
2000. Yarn production has increased from 3,940 mn kg in 1999- 00 to 4,326 mn kg in 2004-05.
Man-made yarn has driven much of this, showing a robust growth of 4.3% in the last five years.
Spun yarn production and the cotton yarn sector have also grown, albeit less impressively,
recording growths of 2.4% and 0.6% respectively.

Source: Ministry of Textiles, GoI

Fabric production has been growing at 2.7% annually between 2000 and 2005, driven primarily
by the smallscale, independent powerloom sector. Growth in the 100% non-cotton segment
touched 5%, followed by cotton fabric at 1.5% and blended fabric at 0.3%. Fabric production
24
touched a peak 45,378 million sq mtrs in 2004-05, and in Nov 06, production recorded a robust
9% growth compared to the corresponding period in the previous year.

Source: Ministry of Textiles, GoI

Trade Scenario

According to the provisional DGCI&S data, textile exports during fiscal 2005- 06 stood at
around US$17 billion, recording a 22% growth year-on-year. Except for man-made textiles, all
segments in the textile industry, including handicraft carpets, wool and silk, have recorded a
growth in exports during 2005-06 -- the first year since the phasing out of the quota system in the
global market.

Readymade garments (RMG) is the largest export segment, accounting for a considerable 45% of
total textile exports. This segment has benefited significantly with the termination of the Multi-
Fibre Arrangement (MFA) in Jan 05. In 2005-06, total RMG exports grew by 29%, touching
US$ 7.75 bn. In 2003-04 and 2004-05, the growth in RMG exports was 8.5% and 4.1%
respectively. The jump in 2005-06 exports has been largely due to the elimination of quotas.

Exports of cotton textiles -- which include yarn, fabric and made-ups -- constitute over 2/3rd of
total textiles exports (excluding readymade garments). Overall, this segment accounts for 26% of
total textile exports. According to the Ministry of Textiles, in 2005-06, total cotton textile
exports Source: Ministry of Textiles, GoI Source: Ministry of Textiles, GoI XVI were worth US$
4.5 bn, implying a growth of 27% over the exports in 2004-05, which were worth US$ 3.5 bn.

25
Man-made textiles exports have witnessed a decline of 2.5% in 2005-06. Between 1999-2000
and 2002-03, man-made textiles exports were growing at around 30% per annum. The slowdown
began since 2003-04 and have been on the decline since.

Major export destinations for India’s textile and apparel products are the US and EU, which
together accounted for over 75% of demand. Exports to the US have further increased since
2005, post the termination of the MFA. Analysis of trade figures by the US Census Bureau
shows that post-MFA, imports from India into the US have been nearly 27% higher than in the
corresponding period in 2004-05.

Segment-wise Exports, 2002-2006 (US$ bn)

Category 2002-03 2003-04 2004-05 2005-06

Cotton Textiles 3.62 3.68 3.54 4.49

Manmade Textiles 1.53 1.86 2.05 2.00

Silk 0.49 0.56 0.59 0.69

Wool 0.29 0.35 0.42 0.47

Ready Made Garments 5.75 5.92 6.02 7.75

Handicrafts 1.42 1.11 1.01 1.24

Jute 0.20 0.25 0.28 0.29

Coir & Coir Manufactures 0.08 0.08 0.11 0.13

Total 13.37 13.80 14.03 17.08

26
Investments

Investments in the textiles sector can be assessed on the basis of three factors:

• Plan schemes such as the Technology Upgradation Funds Scheme (TUFS), Technology
Mission on Cotton, Apparel Parks, etc. -- Under the TUFS scheme, a total of Rs 916 bn has
been disbursed for technology upgradation. There are around 26 Apparel Parks in eight states
in India, with a total estimated investment of Rs 134 bn

• Industrial Entrepreneurship Memorandums implemented from 1992 to Aug 06, amounting to

Rs 263 bn

• Foreign Direct Investments inflows worth US$ 910 mn have been received by the textile
industry between Aug 91 and May 06, which account for 1.29% of total FDI inflows in the
country.

Though significant investments are being made in the textiles segment, the bulk of them are in
the spinning and weaving segments. A cumulative total of US$ 6.67 bn in investment is expected
by 2008. Of this, more than two-thirds is expected in the spinning and weaving segments, while
only 25% is expected in processing and garment units.

Source: Ministry of Textiles

Government Initiatives

The Government’s role in the textile industry has become more reformist in nature. Initially,
policies were drawn to provide employment with a clear focus on promoting the small-scale
27
industry. The scenario changed after 1995, with policies being designed to encourage
investments in installing modern weaving machinery as well as gradually eliminating the pro-
decentralised sector policy focus. The removal of the SSI reservation for woven apparel in 2000
and knitted apparel in 2005 were significant decisions in promoting setting up of large-scale
firms. Government schemes such as Apparel Parks for Exports (APE) and the Textile Centres
Infrastructure Development Scheme (TCIDS) now provide incentives for establishing
manufacturing units in apparel export zones.

The new Textile Policy of 2000 set the ball rolling for policy reforms in the textile sector,
dealing with removal of raw material price distortions, cluster approach for powerlooms,
pragmatic exit of idle mills, modernisation of outdated technology etc. The year 2000 was also
marked by initiatives of setting up apparel parks; 2002 and 2003 saw a gradual reduction in
excise duties for most types of fabrics while 2004 offered the CENVAT system on an optional
basis. The Union Budget of 2005-2006 announced competitive progressive policies, whose
salient features included:

 A major boost to the 1999-established Technology Upgradation Fund Scheme for its
longevity through a Rs 4.35 bn allocation with 10% capital subsidies for the textile
processing sector

 Initiation of cluster development for handloom sector

 Availability of health insurance package to 0.2 mn weavers from 0.02 mn initially

 Reduction in customs duty from 20% to 15% for fibres, yarns, intermediates, fabrics and
garments; from 20% to 10% on textile machinery and from 24% to 16% in excise duty for
polyester oriented yarn/polyester yarn

 Reduction in corporate tax rate from 35% to 30% with 10% surcharge

 Reduction in depreciation rate on plant and machinery from 25% to 15%

 Inclusion of polyster texturisers under the optimal CENVAT rate of 8%

To meet the challenges of the post-MFA setup, the Government of India initiated a reforms
process which aimed at promoting large capital investments, pruning cumbersome procedures
associated with the tax regime, etc. The Textile Vision 2010 was born as a result of interaction
between the government and the industry which envisages around 12% annual growth in the
textile industry from US$ 36 billion now to US$ 85 billion by 2010. Additionally, Vision 2010
also proposes the creation of an additional 12 million jobs through this initiative.

LOGISTICS

Logistics involves the integration of information, transportation, inventory, warehousing,

material-handling, and packaging, and occasionally security. Logistics is a channel of the supply
chain which adds the value of time and place utility. Today the complexity of production
logistics can be modelled, analyzed, visualized and optimized by plant simulation software.
28
LOGISTICS MANAGEMENT

Logistics is the management of the flow of goods, information and other resources, including
energy and people, between the point of origin and the point of consumption in order to meet the
requirements of consumers

TRANSPORTATION

PACKAGING

INVENTORY CONTROL

WAREHOUSING

SUPPY CHAIN MANAGEMENT

29
 CHAPTER 2:

INDUSTRY PROFILE

Bhilosa started as a small textile industry in 1989 from Piparia plant founded by Ramesh Tejrajji
Jain. At that time, he has started tow texturing machine, TFO (Two For One) Twist machine at
Piparia with looms units at Bhivandi.

BHILOSA TEX-N-TWIST PVT LTD (FORMERLY)

In short time, Bhilosa has expanded their business with establishing Two new texturing plant at
17/1/4 & 14/1/1-2, Rakholi , one of the having 36 texturing machine and other is having 10
texturing machine.

BHILOSA INDUTRIES PVT LTD

After Bhilosa focus into POY plant development and started developing customized row
materials for their texturing plant as well as customers. This expanded their yarn business and
subsequently started new plant with chip plant, POY plant, texturings plant all are one roof.
Ramesh Jain has two sons Kumar Jain who is managing director & head officer of marketing
department & Sandeep Jain who is managing director & head officer of factory department.

Bhilosa Industries to expand Manmade Fibre-Partially Oriented Yarn (POY) plant at Rakholi in
Silvassa. Expansion will be within the existing premises. Total cost of the project will be Rs.
148.8 Crores. The details of the products and production capacity will be as per details given
below:

Sr. No. Name of the products Capacity(MT/Day)

1 Synthetic Texturised yarn (Existing) 66.67

2 Partially Oriented Yarn (Proposed) 350

COMPANY PROFILE

30
:: Company Profile:

Backed with 100 years of textile tradition Bhilosa was set up in the year 1989, by Mr. Ramesh
Jain, with an initial production of 580 tones per annum of Draw Textured Yarn. With best
technologies, sharp business acumen, strategic investment and sound fore vision today Bhilosa
can boast of being one of the largest manufacturers of finest draw textured yarn in the country. It
has annual production of 1,05,000 MT of DTY and 80,000 MT of POY and 11,000 MT of
FDY. In a decade of exponential growth Bhilosa has become one of the most diversified, well-
admired and robust organization.

::Management:

Mr. Ramesh Jain is heading the board of directors and the organization as Chairman and
Managing Director

:: Mission:

Growing from strength to strength, Bhilosa produces best quality textile products that meet and
exceed customer needs and expectation of price and quality, it ensures customer satisfaction by
maintaining value driven work culture and it invests in forward and backward integration
projects to maximize returns to the stake holders

:: Vision:

Spin – Weave – Wear.

We seek quantum growth to lead in the domestic market and enhance our international presence
to achieve our above mission.

:: Objectives:

To Maximize returns to the stake holders

To strive for up gradation of skills in the textile sector for effective and efficient growth of the
sector
To maximize returns through efficient operations

To innovate new products and improve standard of services we offer to our customer

31
:: Quality Statement:

Quality of a product or service is not what the supplier ensures, but it is what the customer
realizes and is willing to pay for.

The philosophy of the company is to be innovative & cost competitive

To achieve this target the company is fully equipped with R & D facilities in spinning and
texturising.

Bhilosa has geared up its processes by incorporating even the most trivial information gathered
by their exhaustive explorations.

:: Research & Development:

We commit to continual improvement of our products , processes and systems through

participative involvement of our employees and timely up-gradation of their skills

HISTORY OF BHILOSA:

Time Line:

 In 1989, started small textile industry from Piparia plant

 At this time 2 texturing machine & TFO (Two For One) Twist machine

 Bhilosa has also looms unit at bhivandi

 After, Bhilosa established 2 new texturing plant at rakholi

 After Bhilosa focus into POY plant development and started developing customized
row materials for their texturing plant as well as customers.

 This expanded their yarn business and subsequently started new plant with chip plant,
POY plant, texturings plant all are one roof.

:: Future Plans:

Bhilosa aims to triplicate production of POY and double the production of Draw Textured
yarn.

To set up looms, dyeing and processing houses

To set up CP (Continuous Polymerization) plant

32
LOCATION OF BHILOSA INDUSTRIES PVT LTD:

Factories : SILVASSA (U.T.)

Add: 90/91 Danu Udyog Industrial Estate,Piparia.

Also at survey 17/1/4 &6, Rakholi.

Also at survey 14/1/1& 15/1/2, Rakholi.

Also at survey 14/1/2 Rakholi.

Also at survey 37& 46/1/3/1 Rakholi

33
PRODUCT PROFILE:

 Partially Oriented Yarn (POY)

The Raw material i.e. PET Chips are dried, melted, filtered and then distributed to spinning
manifolds followed by spinning positions to get Partially Oriented Yarn mainly known as POY.
To manufacture POY PET Chips are fed into dryer where the moisture is reduced from 0.3% to
0.003%. After this, chips are melted, filtered through Polymer filter and extruded through the
spinnerets. Extruders are electrically heated microprocessor temperature controlled and screw
speed is controlled and monitored very precisely to ensure uniform quality. The extruded
filaments are cooled by filtered air in the quench chamber with precise temperature control. Air
having no turbulence is used to ensure perfect evenness. High quality anti static lubricating oil is
applied to avoid static charges in the yarn. The filaments are taken through Take-up winders and
wound on bobbins. The POY so made is capable of running on very high speed Draw
Texturising Machines.

Completely automated, vertically integrated POY plant of Bhilosa was commissioned in year
2005 with production capacity of 15000 t/a. In year 2007 Bhilosa doubled its production to
30000 t/a and the current production has enhanced to 80000 t/a. Entire production is for captive
consumption.

Higher Package weight results in increased efficiency and waste reduction

Low breakages in warping and excellent dyeing consistency

Plant Function 24x7

Machinery:

 Chips conveying system (Dense phase) : Coperion Waeschle

34
 Chips Dryer Rosin design : Sathe Engineering

 Low/High Pressure compressors : Kirloskar, Samsung, Atlas Copco

 Chillers Centrifugal / screw type : Trane-USA

 Air Handling Units : Aerotherm

 Main process machinery-High speed : TMT Japan

 Extruders (Microprocess based controlling) : JSW Japan

 Water treatment plant : H. K. Enterprises

 Ultra modern winders (RFR winding) : TMT Japan

 Spintrak : Aspex-USA

35
 Fully Drawn Yarn (FDY)

Fully Drawn Yarn is produced by similar process as POY except that yarn is produced at higher
spinning speed. Intermediate drawing is integrated in the process itself which allows stabilization
through orientation and crystallization. Controlled interface enables this yarn to be twisted in
subsequent operation.

 Higher Package weight increasing efficiency and reducing waste.

 Low breakages in warping and excellent dyeing consistency

 Capacity 11,000 MT per annum

 Plant Function 24x7

36
 DRAW TEXTURED YARN (DTY)

37
Bhilosa offers a wide range of draw textured yarn in Raw white semi dull, Dyed form with all
types of special deniers. The capacity of 8750 MT per month is all about the art of beginning the
value chain on a solid count.

Bhilosa has world’s best technology and one of the most efficient work forces to ensure speedy
deliveries and high service standards.

We offer a wide range of denier from 50 to 600 denier with Intermingled, Non Intermingled,
Intense Intermingled, Low Intermingled etc.

Bhilosa has established a firm reputation in the domestic and export markets for quality and
variety.

Today Bhilosa Industries Pvt. Ltd, is one of the largest exporters of Draw Textured Yarn in
India.

Complete customer satisfaction is the core for unbridled success of Bhilosa Industries Ltd.

Bhilosa’s longstanding reputation of manufacturing excellence relies upon their ability to

consistently supply innovative & high-quality polyester yarns. The Company adds value to the
supply chain through their expertise in new product development and downstream marketing
efforts.

Our production facilities are located in Silvassa, an industrial town, 120 miles from Mumbai the
financial capital of India, and our exports are mainly to Latin American countries as well as
Singapore, Spain, Egypt, Europe etc.

Our network of manufacturing facilities and sales and marketing offices enable us to serve key
customers in all of the world’s major textile and apparel regions.

Today, the textile industry is one of tremendous activity and movement, and it is also one of the
most technologically advanced businesses in the world.

Draw Textured Yarn is manufactured by texturising POY (Partially Oriented Yarn) using
texturising machines. This yarn is suitable for making polyester fabric where end uses could be
garments, furnishings, upholstery etc. In fact this has come as a replacement of cotton and cotton
blended yarns. It has very high durability, high retention properties and low moisture content.

38
Technology

 85 State of Art, High Tech, Microprocessor controlled machinery from world leaders like
ICBT France, Himson under technical collaboration of Reiter Scragg U.K., And
Alidhara.

 Quality comparable with the best in the world.

 Automated packing lines for finished product which ensures uniform textured yarn
packing.

 Automatic material movement.

 A consistent level of high quality anti static lubricating oil is applied for the purpose of
warping.

 Machines equipped with air jets from world leaders in this technology for making
specialized ROTO yarn in fine and coarse denier.

 Optimum mix of high tech machines and high caliber personnel.

 100% operational efficiency via total preventive and predictive maintenance.

39
 PLANT LAYOUT OF COMPANY

• Planning the optimum arrangement of facilities, personnel, equipment, storage space,

material handling equipment and all supporting services, along with the design of the best
structure to contain all these facilities

• Economic handling of all material; better supervision; faster production; better product
quality; flexible plant & workspace design for expansion; Improved work conditions;
unidirectional workflow

Advantages

• Better working conditions for workers

• Minimisation in material handling

• Minimisation in damage & spoilage

• Minimisation of congestion of material, machinery, workers

• Flexibility to adapt to changing production conditions

Types

• Process layout: similar equipment & tasks grouped; also called functional layout; useful for
low volume, high variety jobs

• Advantages:low capital investment,fewer m/c; higher space utilisation;flexibility in

equipment allocation; workers gain expertise; problems localised;job variety

• Disadvantages:needs more space;no mechanisation;high wip;work scheduling

problems;high set-up & inspection costs

Reducing manufacturing costs through improved plant layout is an effective way to improve
profitability.

Lean Manufacturing Solutions Inc. offers the expertise, knowledge, and skills to work with you
to radically reduce costs within your manufacturing facility.

40
 GROUND FLOOR PLANT LAYOUT

MAIN Canteen Despatch Security

OFFICE office office

ENTR

UTILITY DEPATRMENT EXIT

Pr
o W
of A
W R
E
A M P H
W R
A E A A O
C U
R H C K S
E O
H U H I E
N
O S I G A
U E
N R
S & E
A
E E A
R D
A E R E
R A I S
E
A
E P
A
S T
C
H EMERGENCY

EXIT

41
 1ST FLOOR PLANT LAYOUT

QUALITY MANAGEMENT DEPARTMENT

PRODUCTION

OFFICE

P
A M
C
K
A
I C
N
H
G
I
A
R N
E E
A
R
I
E
S

CHAPTER 3:
42
 MACHINERY DETAILS

Himson-specifications:

 Products : Polyester 30-300 denier

 Number of positions : 120/132

 Mechanical speed : 400-1000 m/min

 Draw Ratio : Optional setting value within the above speed Range.

 Direction of Twist : All "Z" or all "S" or alternate "Z" and "S"

 Dimensions : 4150 mm Height

5880 mm width (width over Box Creel)

6540 mm width (width over Rotary Creel)

21345 mm length (Door Closed

ICBT-specifications:

 Products : Polyester 30-300 denier

 Number of positions : 120

 Mechanical speed : 400-1000 m/min

 Draw Ratio : Optional setting value within the above speed Range.

 Direction of Twist : All "Z" or all "S" or alternate "Z" and "S"

43
Alidhra-specifications:

Draw Textrising Machine ( AFT-11HS)

 Number of positions : 216-24-312

 Construction : Two side, Three deck

 Aplication : Producing crimp and Textured yarn from Nylon,

Polyester, P.P., P.A. etc. P.O.Y.

 Denier Range : 50 to 1000

 Mechanical speed : 1200 met./min.

44
AIR DRAW TEXTURISING MACHINE 800

 Number of positions : 216-24-88-312

 Construction : Two side, Three deck

 Denier Range :UP to 600

 Mechanical speed : 1200 met./min.

45
 CHAPTER 4:

MANPOWER

Organizanal chart of production department where is handled manpower from Top to Bottom.

Production
manager

In charge In charge

Ground floor 1st floor

4 supervisors 4 supervisors

Operators Helpers Loaders Operators Helpers Loaders

This information of the Rakholi plant where produce only texturiesed yarn in Bhilosa
Industries Pvt Ltd

Plant: 14/1/2

Production manager- 1(Hitesh chovatia)

Machine – 36 Texturing machine

Production manager- 1

In charge - 2

Supervisor – 8 (1 per 4 machine)

Operators -2 per machine

Helper – 1 per machine

46
Utility – as per required

Quality – as per required

Mechanical – as per required

Total employees in the company : 650 including contract worker

47
 CHAPTER 5:

ROLE OF RAW MATERIALS, PRODUCTION PROCESS AND FINISH GOOD

 Raw materials

Raw materials is main initial for manufacturing, whenever lack of raw materials may be
interrupt of production process. In the other hand, stock of raw materials is more than enough it
will be increased waste & unnecceary capital investment so each and every stage procurement of
the raw materials is beneficial for production cost. Bhilosa is manufacturing of raw material to
final goods and also sale in the market so in this plant totally inward raw materials from POY
plant.

FOR POY PLANT

¤ PET Chips :

48
PET Chips, also known as Polyester Chips or Polyethylene Terephthalate Chips is the base of
any type of plastics & polymer. Depending on the processing, PET may exist both as an
amorphous (transparent) commonly known as Bright or Super Bright Chips and as a semi-
crystalline material commonly known as PET Semi-Dull Chips.

PET Chips are also used to make PET Film. High quality chips without Silica & CiO2 contents
are used to make PET Film.Whereas another type of Chips variant is Bottle grade chips used in
making different types of plastic bottles depending on the Intrinsic Viscosity.Kayavlon Impex is
a leading supplier of PET Chips from India, China, Taiwan & has been exporting world class
quality polyester chips to various countries across the globe. We supply polyester chips suitable
for various applications. Mainly PET Chips are categorised into three grades – Textile grade,
Bottle grade and Film grade.

Textile Grade

Textile-grade polyester chips are used for making the Polyester Filament yarn like POY, FDY
and Staple fibre. The Yarn grade (Textile grade) chips are available in Super Bright, Semi Dull,
Cationic Semi Dull & Cationic Super Bright PET Chips.

PET Chips For Textile Grade :

We are the leading indenters of quality textile products and PET Chips from China, India,
Taiwan & Korea. PET Chips used in Textile Industry is also known as Fibre grade PET chips,
filament grade PET chips or textile grade PET chips. Textile grade PET Chips are used for

49
making Polyester Filament yarn like POY, FDY and Staple fibre used widely in the Textile
industry.

The Yarn grade or Textile grade chips are available in Super Bright (BR Chips), Semi Dull
(SD Chips), Cationic Semi Dull and Cationic Super Bright PET Chips (CD Chips).The
process of making PET Chips consists of mixing a thermoplastic polyester-resin material with an
alumina tri-hydrate (ATH) filler and with a pigment, if desired, in a heated extruder to produce a
continuous stream of thermoplastic agglomerate. This product is allowed to cool, then it is cut,
ground and screened to a predetermined size, as required to meet the size characteristics of the
desired resin-chip product.

With our extensive reach with the top-most authorities of PET Chips manufacturers, we can
supply you best quality Polyester chips from manufacturers & suppliers in China, India,
Taiwan, Malaysia & Korea.

Polyester Partially Oriented Yarn, commonly known as Polyester POY is the primary form of
Polyester yarn. It is also known as Polyester Pre-Oriented Yarn. It is the first form of yarn
made directly from PTA & MEG or by spinning Polyester PET Chips. POY is mainly used in
texturizing to make textured yarn, also known as Polyester Drawn Textured Yarn (DTY). POY
can also be used in draw warping for weaving and warp knitting of fabrics.

POY yarn is available in different lustre like Semi-Dull POY and Bright POY. The Bright POY
has the shine in it due to the cross-sections in the filaments. The fabric made from Bright POY
also has the bright lustre. Polyester POY yarn is mainly available in Raw White color & is also
available in various different colors. POY is usually colored by the Dope Dyed technology as it
is more efficient & the yarn gets evenly colored at each & every part. Color master-batch is
mixed with the raw material to make the dope dyed POY. Dope dyed POY yarn can be used to
make the Dope Dyed DTY yarn.

50
 FOR FDY

Polyester FDY is the abbreviation for Polyester Fully Drawn Yarn. It is also know as
Polyester Filament Yarn (PFY) or Spin Draw Yarn (SDY). FDY is mainly used as weft or
weaves in making fabrics. FDY can be knitted or woven with any other filament yarn to get
fabric of various different varieties. It is mainly used in Home Furnishing Fabrics, Fashion
Fabrics, Denim, Terry Towel and others.

FDY yarn is mainly available in 3 lustre - Semi-dull (SD), Bright (BR) having circular
section & Triloble Bright (TBR) having triangular cross-sections. Filament yarn having
trilobal bright lustre is widely used in making curtains, bed-sheets and carpets. FDY is available
in Raw-white as well dope dyed. Dope Dyed FDY yarn can be used to make the colored fabric
directly instead of making the fabric with FDY Raw-white first & then dyeing it. Catonic FDY is
another variation of Filament yarn. Catonic FDY yarn is made from Catonic PET Chips.

FOR DTY

Drawn Textured Yarn (DTY) yarn is obtained when Polyester POY is simultaneously twisted &
drawn. DTY yarn is mainly used in weaving & knitting of fabrics for making clothes, home
furnishings, seat covers, bags and many other uses. DTY yarn can be in Semi Dull or Bright or
Triloble Bright depening upon the type of sections of filaments.

Technical Properties of DTY yarn can be moulded in several ways to make the yarn suitable for
its vast uses. Different heating techniques can be used to make the yarn set for specific use - 1
Heater DTY is normally woolly & more stretchable as compared to DTY with 2 Heater. Also the
DTY yarn can be made with several combinations of Intermingle points - it can be Non-
Intermingle (NIM) having 0 - 10 knots/meter or Semi-Intermingle (SIM) having 40 - 50
knots/meter or High-Intermingle (HIM) having 100 - 120 knots/meter. These knots are not
actually the knots tied when two threads are broken but they are the tangle knots created by
heating pressure. These Intermingle yarns, also known as Interlaced yarn, are the replacement
for lightly twisted yarns. Polyester DTY yarn can also be twisted to high twists like 1500 TPM or
4000 TPM (twist per meter). Such twisted yarn can also be heat-set to make the yarn
permanently thermo-set the twist. Catonic DTY is another variant of Polyester DTY that is
mainly used in blankets. Catonic DTY is made from Catonic PET Chips

51
 Texturing process in BHILOSA

To give synthetic yarns special properties such as stretch, bulk and the appearance of natural fibers.

The false twist texturing principle For the texturing process the texturing industry has the choice
of a variety of DTY machines produced by various manufactures around the world. False twist
texturing machines, regardless who offers them, all work on the same principle. The schematic
below shows the most important steps in the manufacturing of DTY.

POY, which stands for Partially Oriented Yarn, is now the standard feed yarn for the texturing
process. It is a continuous filament yarn spun at a speed, which is, for example for polyester,
around 3200 m/min.

Shaft 1 is the input feeding device for the POY. From here the yarn is fed to Shaft 2. When POY
is fed into the machine, the yarn has to be drawn. The speed of shaft 2 is always higher by the
factor of the necessary draw ratio for the particular yarn and process. The yarn is simultaneously
twisted and drawn. The twisting is done with a friction device, such as a set of rotating friction
disks. But there are other twisting devices such as belts. After Shaft 1 there is a yarn heater,
which heats the yarn to a temperature where it can be thermo-set. Right after the heater is
normally a cooling plate, which must cool the yarn to a substantially lower temperature in order
to permanently thermo-set the twist. As the yarn is released from Shaft 2 we observe how each
single filament is trying to assume the three dimensional helix formation it was set in. The result
is a voluminous bulked stretch yarn.

52
What type of yarns can be textured?

Synthetic filament yarns made from polyester, nylon and polypropylene. Polyester yarns are
normally in the range between 50 and 300 den, with the emphasis on 75 and 150 den. Nylon
yarns are in the range from 15-110 den, with the majority of fine hosiery yarns being 20 den and
coarser yarns being 70 den.

53
 Finished good

Draw textured yarn is manaufactured by texturing POY (partially Oriented Yarn) using
texturising machine. This yarn is suitable for making polyester fabric where end uses could be
garments, furnishings, upholstery etc. In fact this has come as areplacement of cotton and
cotton blended yarns. It has very high durability, high retention properties and low moisture
content.

When bhilosa born in 1889, it has produced annual production of 580 tones of Textured yarn.
Today Bhilosa’s production capacity has reached to 1,05,000 MT of Draw Textured Yarn per
annum Bhilosa can manufacture wide range of Textured Yarn from 50 to 6oo denier and 4 to
filament in different permutation and combination. And this establishes Bhilosa as an industry
of repute in this segment of textiles.

54
55
 CHAPTER 6:

QUALITY CONTROL:

A manufacturer has a conventional belief that it is very hard and costs very high to ensure quality
of a product. Quality of a product is the one that ensures correct use to the customer and the
customer pays money for it. This constitutes quality. With stringent quality control measures and
best QC equipments we have been able to achieve what we have believed in.

This research will be important in each manufacturing process. The major objective of quality
control to improve quality as per customer need and productivity. Bhilosa Company is having
quality management department on the plat. it is check quality inward and outward stock in the
company

Sample:

Each and every product are not possible to check quality. so they are take some sample of per
machine. Almost they check 5 samples per machine or as per required for best quality.

What is check?:

- Denier

- Strength

- Elongation

- Shrinks

- Nips per meter

- Dyed peak up

Tools to be used:
56
- Tensile machine

- Dyed tools

- Measurements tools of yarn

Report:

All the report checked by quality lab manager whenever some problem of quality manager will
take action immediately and send message to production manager. After they change in
production process.

57
 CHAPTER 7:

ROLE OF IT IN WAREHOUSING AND PACKING

Technology is everywhere, so role of IT is helpful of data record in particular forms and send
message via email, EDI form factory to warehouse and main office. Bhilosa is using message
transfer software for data sending. Bhilosa uses bar-coding system on their factory. It helpful for
easy data collect with computerized system.

BAR CORDING SYSTEM

Bhilosa is using Intercom massaging software in their plant & offices for better data & report
send between shop floor to top management. They installed quick massaging system in their
company

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 CHAPTER 8:

MATERIALS HANDLING AND PACKAGING SYSTEMS

Material Handling is the movement, storage, control and protection of materials, goods and
products throughout the process of manufacturing, distribution, consumption and disposal. The
focus is on the methods, mechanical equipment, systems and related controls used to achieve
these functions. Bhilosa use material handling tool as like hand trolley, complex conveyor belt,
pallet, and forklift.

Material handling equipment is used to increase throughput, control costs, and maximize
productivity. There are several ways to determine if the material handling equipment is achieving
peak efficiency. These include capturing all relevant data related to the warehouse’s operation
(such as SKUs), measuring how many times an item is “touched” from the time it is ordered until
it leaves the building, making sure you are using the proper picking technology, and keeping
system downtime to a minimum.

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packaging systems

Packaging is the science, art and technology of enclosing or protecting products for distribution,
storage, sale, and use. Packaging also refers to the process of design, evaluation, and production
of packages. Packaging can be described as a coordinated system of preparing goods for
transport, warehousing, logistics, sale, and end use. Packaging contains, protects, preserves,
transports, informs, and sells.In many countries it is fully integrated into government, business,
institutional, industrial, and personal use.

Package labelling labeling is any written, electronic, or graphic communications on the

packaging or on a separate but associated label.

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PACKAGING SYSTEMS

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 CHAPTER 9:

WAREHOUSING & TRANSPORTATION

WAREHOUSING

A warehouse is a commercial building for storage of goods. Warehouses are used by

manufacturers, importers, exporters, wholesalers, transport businesses, customs, etc. They are
usually large plain buildings in industrial areas of cities and towns. They usually have loading
docks to load and unload goods from trucks. Sometimes warehouses load and unload goods
directly from railways, airports, or seaports. They often have cranes and forklifts for moving
goods, which are usually placed on ISO standard pallets loaded into pallet racks.

Modern trends

Traditional warehousing has declined since the last decades of the 20th century, with the gradual
introduction of Just In Time (JIT) techniques. The JIT system promotes product delivery directly
from suppliers to consumer without the use of warehouses. However, with the gradual
implementation of offshore outsourcing and offshoring in about the same time period, the
distance between the manufacturer and the retailer (or the parts manufacturer and the industrial
plant) grew considerably in many domains, necessitating at least one warehouse per country or
per region in any typical supply chain for a given range of products.

Recent retailing trends have led to the development of warehouse-style retail stores. These high-
ceiling buildings display retail goods on tall, heavy duty industrial racks rather than conventional
retail shelving. Typically, items ready for sale are on the bottom of the racks, and crated or
palletized inventory is in the upper rack. Essentially, the same building serves as both warehouse
and retail store.

Large exporters/manufacturers use warehouses as distribution points for developing retail outlets
in a particular region or country. This concept reduces end cost to the consumer and enhances the
production sale ratio.

Bhilosa Company has more space for warehousing in theirs plant. They is use of raw materials in
other plant so no more required purchasing raw material outside therefore they has more
required space for warehousing.

An automated storage and retrieval system (ASRS or AS/RS) consists of a variety of

computer-controlled methods for automatically placing and retrieving loads from specific storage
locations. Automated Storage and Retrieval Systems (AS/RS) are typically used in applications
where there is a very high volume of loads being moved into and out of storage where storage
density is important because of space constraints, and where no value adding content is present
in this process.

Some warehouses are completely automated, and require no workers inside. Pallets and product
move on a system of automated conveyors, cranes and automated storage and retrieval systems
coordinated by programmable logic controllers and computers running logistics automation
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software. These systems are often installed in refrigerated warehouses where temperatures are
kept very cold to keep product from spoiling, and also where land is expensive, as automated
storage systems can use vertical space efficiently. These high-bay storage areas are often more
than 10 meters (33 feet) high, with some over 20 meters (65 feet) high.

For a warehouse to function efficiently, the facility must be properly slotted. Slotting addresses
which storage medium a product is picked from (pallet rack or carton flow), and how they are
picked (pick-to-light, pick-to-voice, or pick-to-paper). With a proper slotting plan, a warehouse
can improve its inventory rotation requirements—such as first in, first out (FIFO) and last in,
first out (LIFO)—control labor costs and increase productivity.

TRANSPORTATION

The act of transporting, or the state of being transported; carriage from one place to another;
removal; conveyance.

Bhilosa has contracted with transportation company which to delivery of good from factory to
customer, it best deal with reducing transportation cost because of investing lot of working
capital in transportation facility & Bhilosa company has committed with customer to right time
delivery at right place .

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 CHAPTER 10:

ANALYSIS AND INTERPRETATION OF DATA

Bhilosa industries produce textured yarn with monthly data analysis.

Month June July August September October November

Production 2647 3049 2976 3027 3036 3307

(tons)

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 CHAPTER 11:

FINDINGS AND CONCLUSIONS:

Production is a very creative activity in every business organization. Every product produced
within an industry has to be quality wise as per need customer other wise it will remain as unsold
stock, which will be of no value. I have realized this fact after completion of my winter training
project. Despite of various difficulties and limitations faced during my winter training project on
the topic “ANALYSIS OF MANUFACTURINGS & LOGISTICS MANAGEMENT IN
BHILOSA INDUSTRIES PVT LTD” I have tried my level best to find out the most relevant
information for the organization to complete the assignment that was given to me. After
completion of my summer training project I have gained several experiences in the field or
production management. I have got the opportunity to meet various people, which concern in
deferent department in the company. This winter training project has given me the opportunity to
have first experience in the corporate world.

Theoretical knowledge of a person remains dormant until it is used and tested in the practical
life. The training has given to me the chance to apply my theoretical knowledge that I have
acquired in my classroom to the real business world. I have completed my winter training project
in which are involved in its successful completion. In spite of few limitations and hindrance in
the winter training project I found that the work was a challenge and fruitful. It gives enough
knowledge about the yarn manufacturing and the distribution process undertaken by an
organization. This winter training project has enabled my capability in order to manage business
effectively and in my career in future.

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 CHAPTER 12:

BIBLIOGRAPHY:

 Everett E., Adam, Jr. Ronald J Ebert (2007): “Production & operations management” (fifth
edition), Prentice-Hall of India Pvt. Ltd., New Delhi-110 001

 As also under the guidance of Hiteshbhai chovatia who is production manager in Bhilosa
Industries Pvt. Ltd.

 Mahesh who In charge of electronics department & his colleagues help me in give
information about Bhilosa Industries Pvt. Ltd.

 Bhilosa’s records, brochures, and manuals

 www.bhilosa.com

 www.madehow.com

 www.dnb.co.in

 www.google.co.in

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