INTRODUCTION

Spinning is an ancient textile art in which plant, animal or synthetic fibers are twisted together to form yarn. For thousands of years, fiber was spun by hand using simple tools, the spindle and distaff. Only in the High Middle Ages did the spinning

wheel increase the output of individual spinners, and mass-production only arose in the 18th century with the beginnings of the Industrial Revolution. Hand-spinning remains a popular handicraft. The Spinning is a technological system in which twist is inserted to the fibers and yarn is produced. The spinning process includes many processes which transforms the bales of raw cotton into a yarn ready for weaving. The term "spinning" can refer to the whole activity or just to the final process of making the yarn. The raw cotton arrives in the form of large bales. These are broken open and a worker feeds the cotton into a machine called a "breaker" which gets rid of some of the dirt. The cotton may not be consistent in quality from bale to bale therefore samples are taken before getting bales in best quality.

Natural fiberscotton, flax, silk, and woolrepresent 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 plainweave 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 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. The fibers used in the textiles industry as raw material could be broadly classified into: 1. natural fibers. 2. Man made fibers.

The natural fibers could be grouped into a. Vegetable cotton, jute, etc. b. Animal (Silk and Wool), and, c. Mineral (Gold, Silver Aluminum etc.) Man-made fibers could be broadly categorized into: i. ii. Degenerated, and, Synthetic Fibers.

Among the degenerated fibers, there protein fivers (cess in, alginate etc.) and cellulosic fibers (viscose, poly nosic etc.) the category of the synthetic man/made/fivers included polyester, polyamide and acrylic etc. Cotton is the most widely used textiles fiber today. After the cotton crop is harvested the kapas has to be ginned in order to separate fiber from the seeds. After ginning, the cotton is available in a loose opened form. For convenience of handling and transposition, cotton is compressed and packed into bales. The quality of cotton is judge in terms of its Grade and Staple.

The grading of cotton done with reference to impurities such as leaves, sand, dust, broken, seeds naps, moles and color of cotton. But the fiver properties of cotton are judged mainly by the length of the fiber i.e. the Staple length. Quality of cotton depends on its physical properties viz. length, fitness, strength and maturity by etc. India Spinning Industry has gone from strength to strength since a very long time now as it was the hub of cotton manufacturing. Cotton is not only consumed to the highest extent in India but it has also become one of the most profitable textiles in the export industry. Spinning in India can be classified into 2 categories: medium and long staple. But there was a shortfall in the 'extra-long' category that continued for many years. There was a massive downfall in the cotton spinning in India during 2004-2005. The production rate of cotton was about 4 lakh bales that was less by 5 lakh bales from the required rate which was 9 lakh bales. Mr. P. D. Patodia, the Chairman of the Standing Committee on Cotton, CITI-CDRA said that the manufacturing of cotton will rise to 11-12 lakh bales in 2010. The present downfall in the cotton production has witnessed a 50% increase in the price of Indian varieties of ELS, which is detrimental for the spinning industry in India. Spinning mills require domestic accessibility of ELS cotton in increased quantity and of better fiber qualities.

INDUSTRY PROFILE
The textile industry is a term used for industries primarily concerned with the design or manufacture of clothing as well as the distribution and use of textiles.Prior to the manufacturing processes being mechanized, textiles were produced in the home, and excess sold for extra money. Most cloth was made from either cotton or flax, depending on the era and location. By the end of the 16th century, cotton was cultivated throughout the warmer regions in Asia and the Americas. In Roman times, wool, linen and leather clothed the European population: the cotton of India was a curiosity that only naturalists had heard of, and silk, imported along the Silk Road from China, was an extravagant luxury. The use of flax fibre in the manufacturing of cloth in Northern Europe dates back to Neolithic times. Cloth was produced in the home, and the excess woven cloth was sold to merchants called clothiers who visited the village with their trains of pack-horses. Some of the cloth was made into clothes for people living in the same area and a large amount of cloth was exported. The process of making cloth depends slightly on the fiber being used, but there are three main steps: preparation of fibers for spinning, spinning, and weaving or knitting.

The key British industry at the beginning of the 18th century was the production of textiles made with wool from the large sheep-farming areas in the Midlands and across the country (created as a the a result tools of of land-clearance the trade of

and enclosure). Handlooms and spinning the weavers in their cottages, and

wheels were this was

labour-intensive

activity

providing employment throughout Britain, with major centers being the West Country. The textile industry grew out of the industrial revolution in the 18th Century as mass production of clothing became a mainstream industry. Starting with the flying shuttle in 1733 inventions was made to speed up the textile manufacturing process. In 1738 Lewis Paul and John Wyatt patented the Roller Spinning machine and the flyer-and-

bobbin system. Textile mills originally got their power from water wheels, and thus had to be situated along a river. With the invention of the steam engine, in the 1760s to 1800s, mills no longer needed to be along rivers. By the later 20th Century, the industry in the developed world had developed a bad reputation, often involving immigrants in illegal "sweat shops" full of people working on textile manufacturing and sewing machines being paid less than minimum wages. This trend has resulted due to attempts to protect existing industries which are being challenged by developing countries in South East Asia, the Indian subcontinent and more

recently, Central America.

Whilst globalization has seen the manufacturing outsourced to overseas labor markets, there has been a trend for the areas historically associated with the trade to shift focus to the more white collar associated industries of fashion design, fashion modeling and retail. India Textile Industry is one of the leading textile industries in the world. Though was predominantly unorganized industry even a few years back, but the scenario started changing after the economic liberalization of Indian economy in 1991. The opening up of economy gave the much-needed thrust to the Indian textile industry, which has now successfully become one of the largest in the world. India textile industry largely depends upon the textile manufacturing and export. It also plays a major role in the economy of the country. India earns about 27% of its total foreign exchange through textile exports. Further, the textile industry of India also contributes nearly 14% of the total industrial production of the country. It also contributes around 3% to the GDP of the country. India textile industry is also the largest in the country in terms of employment generation. It not only generates jobs in its own industry, but also opens up scopes for the other ancillary sectors.

India textile industry currently generates employment to more than 35 million people. It is also estimated that, the industry will generate 12 million new jobs by the year 2010. Indian textile industry can be divided into several segments, some of which can be listed as below:

Cotton Textiles Silk Textiles Woolen Textiles Readymade Garments Hand-crafted Textiles Jute and Coir

COMPANY PROFILE
ABOUT KUMAR SPINNING MILLS Kumar Spinning Mills Private Ltd an ISO 9001:2000 company started at the year of 1990, a major yarn producer and manufactures. It is located at krishanapuram, 6km from palayamkottai. Total area of industry is 15 acres. Only 30 percent of the area is utilized for the industry buildings. In 1990 the Kumar Spinning Mills Private Limited has started with 3000 spindles. The main product is Reeling yarn and Cone yarn. In early stage the yarn produced was used for bet sheet and towels. The count of yarn spun were 20s, 30s, 2/20s. The turnover was around rupees 2 crores per annum. The number of labours employed was 70. In 1995 the mill was expanded the spindles with 3000 and the total spindles was 6000. The count of yarn spun were 20s, 30s, 40s, and 2/20s. The turnover was around rupees 5 crores per annum. The quality of yarn was improved from weft to warp. The number of labours employed was 120. In the year 2000, the mill was expanded the spindles with 4000 and the total spindle was 10000. The turnover of the company was around Rs.10 crores per annum. The quality of yarn was improved from warp to hosiery.

In 2003, the mill has expanded the spindles up to 12000, with latest machineries imported from foreign countries. The counts of yarn spun were 20s, 30s, 40s, and 52s. The turnover of the company was around Rs. 12 crores per annum. The number of labours employed was 250. The yarn was supplied to number one brand customer like SANKU MARKS, 144, 3MANGOES, KIBS, etc. In the year of 2005 the mill is having 15000 spindles with latest machineries from leading machineries manufacturers. And the company gets the auto cone winding machine, which gives quality of yarn production. Now the year of 2010 the company only having 107 ladies and 69 men labours in industry totally 192 workers are working in the company, because the power cut the government orders to the spinning mills have only running 60 percentages of machineries and so the company gives retirement to their employees. There is three shift production are done in Kumar Spinning Mills Private Limited.

The shift times are as follows.

o o o

Shift 1 working time (7am -3pm) Shift 2 working time (3pm -11pm) Shift 3 working time (11pm -7am)

CUSTOMERS

Palani mudaliyar & co. Sri ram textiles. Saravana fabrics. C.S exports. Dharshini pvt ltd.

COMPETITOR PROFILE
Sri Gomathi Mills Private Limited

Ganapathy Mills Limited

Subburaj Spinning Mills Private Limited

PRODUCT PROFILE
Kumar Spinning Mills Private Limited company main production is Yarn. The yarn will be used for weaving clothes. Yarn is a long continuous length of interlocked fibers, suitable for use in the production of textiles, sewing, embroidery and rope making . They are converting cotton into two main products, they are

Hank yarn Cone yarn

Hank yarn:
Hank refers to a unit of yarn or twine that is in a coiled form. This is often the best form for use with hand looms, compared to the cone form needed for power looms. Hanks come in a fixed length depending on the type of material, so the term hank is sometimes used as a unit of measure.

Cone yarn:
A yarn cone is a stiff cardboard or plastic cone used to store yarn. Many types of thread or yarn can be purchased on these cones, including cotton, wool, polyester or a blend of these materials. Small cones might hold 1400 to 1800 yards (1280.16 to 1645.92 m). Larger cones can store from 3360 to 6550 yards (3072.38 to 5989.32 m). Smaller cones are typically used on knitting or weaving machines designed for household use, while large cones might be used in an industrial setting. Most yarn that comes only come in cone is for weavers.

COUNT TYPE:
Both the hank and cone yarn product is different on their count value. The counts are

20s 30s 40s 50s 60s 64s 72s 120s

YEAR SCALE VALUE: April 2009 march 2010

PERIOD 2010 April May June July August September October November December January February March TOTAL

2009- QUALITY CLEARED 95651 87504 86510 75622 78359 73492 94650 83584 84810 79682 80359 93321 1013544

EX-MILL VALUE 10848689 10254876 10656898 10447653 10347153 10154890 10748629 10154976 10359892 10327659 10047953 10892929 125242197

CHARITY VAT

NET AMOUNT

3394 2980 2790 2330 2743 3017 3694 2700 3190 2340 2613 3676 35467

374407 319044 298876 305488 320071 330110 373907 309044 308876 315485 318070 278922 3852300

11322142 10664404 11045074 10831093 10748326 10561509 11220880 10550304 10756768 10725166 10448995 11268848 13,01,43,509

YEAR 2005 2006 2007 2008 2009 2010

NET SALES(AMOUNT IN RUPEES) 10,36,56,730 11,82,933,617 13,32,40,169 11,43,68,455 10,12,20,248 13,01,43,509

SOURCE OF MATERIAL:
Spinning mills receive raw materials both cotton and man-made fibers normally in the form of bales, in Lorries. In the case of cotton, a bale weighs about 170 kg whereas a synthetic fiber bale weighs around 300 kg. On arrival, these bales are first stored in godowns, up to 10 feet height, in multiple layers, i.e., one above the other and then transported to the mixing department. The largest producers of cotton, currently, are China and India, with annual production of about 34 million bales and 24 million bales, respectively; most of this production is consumed by their respective textile industries. The largest exporters of raw cotton are the United States, with sales of $4.9 billion, and Africa, with sales of $2.1 billion.

India is the third largest producer of cotton and its derivatives in the world. The states in India producing cotton crop are

Maharashtra Gujarat Andhra Pradesh Haryana

Punjab

Kumar spinning mills uses the following varieties of cotton they are,

a. J-34 b. RG-34 c. F-414 d. MCU-5 e. MECH-1 f. DEC-32 g. LK h. SANKAR-4

MANUFACTURING PROCESS STRUCTURE:

Cotton which is in the form of bale is fed to blow room followed by various operation like carding and coming depends on the requirements. The Spinning is a technological system in which twist is inserted to the fibers and yarn is produced. The spinning process includes many processes which transform the bales of raw cotton into a yarn ready for weaving. The term "spinning" can refer to the whole activity or just to the final process of making the yarn.

The spinning process is shown in the following diagram. MANUFACTURING PROCESS MIXING ROOM:

In spinning mill production the first process is done on the mixing room. In this room chemical and water will be spread over the cotton before entering the machine. In the mixing room the function of cleaning the cotton and their seeds and dust is done. 10 to 20 percentage of cotton is cleaned at this department.

Mixing of cotton brought to make a uniform blend in order to make a uniform yarn with high quality parameter in order to avoid any shade problem. For this purpose, the number of bales is mixed to get uniform results. Raw cotton is purchased from best Cotton growing areas of country and also cotton bales are imported from foreign countries. For stocking and mixing, sandwich-mixing technique is used.

BLOW ROOM: At blow room more then 80 percent of dust and seeds are removed. The cylinder form of cotton is made i.e. 50 to 60 meters lap. A lap is a sheet of cotton fleece rolled around an

iron rod inserted in the lap spindle. When the full lap is removed from the sketchers, the spindle is pulled out and the lap remains around the iron rod.

CARDING: This process is the Heart of the Mill where converting the cylinder type cotton into sliver form is done. The opened fibers are collected by the doffer comb or the doff roller in the form of a web. This web is then passed through the trumpet to give it the shape of a rope and coiled inside a can by means of a coiler. The rope form of cotton material is called a sliver.

The card is the most important machine in the yarn manufacturing process. It performs second- and final-level cleaning functions in an overwhelming majority of cotton textile mills. The card is composed of a system of three wire-covered cylinders and a series of flat, wire-covered bars that successively work small clumps and tufts of fibres into a high degree of separation or openness, remove a very high percentage of

Trash and other foreign matter, collect the fibres into a rope-like form called a sliver and deliver this sliver in a container for use in the subsequent process

COMBING: Combing is a technique that has been used in the preparation of textiles for centuries. Essentially, combing is a process that helps to smooth and prepare fibers for use in spinning. Combing also helps to separate short fibers from longer ones, which also helps to make the process of spinning much easier. The combed cotton will feel smoother to the touch, and also produce a garment that will wear longer than a garment made with uncombed cotton.

A small number of mills produce combed yarn, the cleanest and most uniform cotton yarn. Combing provides more extensive cleaning than is provided by the card. The purpose of combing is to remove short fibres, neps and trash so that the resulting sliver is very clean and lustrous. The comber is a complicated machine composed of grooved feed rolls and a cylinder that is partially covered with needles to comb out short fibers. DRAWING:

In order to spin an even and regular yarn the silver should be uniform and regular. The fibers should also be made parallel and oriented along the axis of the silver for better control of the fibers during drafting in succeeding process and also for obtaining better strength of yarn in spinning. The evenness of silver and parallelization of fibers are achieved at the draw frame where 6 to 8 or more silvers are blended together and drafted to get one silver. The draft will be equal to the no of silvers blended. Drawing is the first process in yarn manufacturing that employs roller drafting. In drawing, practically all draft results from the action of rollers. Containers of sliver from the carding process are staked in the creel of the drawing frame. Drafting occurs when a sliver is fed into a system of paired rollers moving at different speeds.

Drawing straightens the fibres in the sliver by drafting to make more of the fibres parallel to the axis of the sliver. Parallelization is necessary to obtain the properties desired when the fibres are subsequently twisted into yarn. Drawing also produces a sliver that is more uniform in weight per unit of length and helps to achieve greater blending capabilities. The fibres that are produced by the final drawing process, called finisher drawing, are nearly straight and parallel to the axis of the sliver. Weight per unit length of a finisher-drawing sliver is too high to permit drafting into yarn on conventional ring-spinning systems.

SIMPLEX: We have come from blow room to carding to draw frames and now we enter the frames department also called as roving department or simplex department. Simplex department are used to increase the yarn quality and strength. The hank cotton is converted in to bobbin at this department. The bobbins colors are red, yellow, and ash color. The hank with bobbin weights is 1kg to 1.5kg each.

SPINNING: In this spinning department the rover yarn will be more thinned at this section. Before the simplex department we called the cotton name as hank, but at the stage of entering the hank into the spinning department it is called as yarn. The spinning department is having 15000 spindles, which helps to making yarn production. The spinning department converts the big bobbin hank into small bobbin; the weight of small bobbin weight to 50 to 55grams only. The spinning department is converting the 1000 meter hank onto 26000 meter yarn.

Spinning is the single most costly step in converting cotton fibres to yarn. Currently, over 85% of the worlds yarn is produced on ring-spinning frames, which are designed to draft the roving into the desired yarn size, or count, and to impart the desired amount of twist. The amount of twist is proportional to the strength of the yarn. The ratio of the length to the length fed can vary on the order of 10 to 50. Bobbins of roving are placed onto holders that allow the roving to feed freely into the drafting roller of the ring-spinning frame. Following the drafting zone, the yarn passes through a traveller onto a spinning bobbin. The spindle holding this bobbin rotates at high speed, causing the yarn to balloon as twist is imparted. The lengths of yarn on the bobbins are too short for use in subsequent processes and are doffed into spinning boxes and delivered to the next process, which may be spooling or winding.

REELING: Reeling department helps to create a reeling yarn using for handloom production. That is silk sarees, cotton sarees handloom production. It is the raw material for handloom products. In this department 12 machines are used for production purpose. The following types of reeling are available, they are

a. Single hank plain reel (SHPR) b. Double hank plain reel (DHPR)

c. Double hank cross reel (DHCR) PACKING: It is the final process. The finished yarn will be packed neatly and send to the customer. The packing is base on the following type

A. Cone yarn weight

o o

40 cone = 50kg 50 cone = 50kg

B. Reeling yarn weight

o o

40 bundle = 200kg (1 = 5 kg) 20 bundle = 90kg (1 = 4.5 kg)

NEED FOR THE STUDY

SCOPE OF THE STUDY

COMPANY STRUCTURE
DEPARTMENT STRUCTURES In Kumar Spinning Mills Private Limited the following functional department are available, they are

Accounts department

Administrative department Marketing department Production department Purchase department Quality department

ACCOUNTS DEPARTMENT: The accounting department typically handles everything that keeps the business running. It depends on the company. For most though, it means keeping the books. That means maintaining checking accounts, payroll, tax preparations, financial statement preparations, analyzing the companys profitability, meeting with regulators and auditors, creating budgets, etc..,

ADMINISTRATIVE It is a universal process of organizing people and resources efficiently so as to direct activities toward common goals and objectives. The manager is full responsible for the administrative works. There are 11 permanent workers are working in administrative. Functions:

Send the product information to the main office. Assistants salary. Attendance control.

MARKETING Marketing is perhaps the most important activity in a business because it has a direct effect on profitability and sales. Marketing is basically your interaction with your consumer. This interaction with your consumer is done so that you can get the consumer to purchase your product or service. Basically that is what marketing is all about. Marketing should be done for the right product, in the right place, at the right time, at the right price.

PRODUCTION DEPARTMENT The act or process of producing something the function of the production departments in a company is to take inputs and fashion them into outputs for customer use. The goal of production and operations is to create an end product in the most economic and efficient way possibly. PURCHASE DEPARTMENT

Purchase is the most important and necessary department in the spinning mill. This helps to get continuous available of raw material to the company. The purchase of cotton is estimated by the word bale. QUALITY CONTROL DEPARTMENT: Quality control is a process by which entities review the quality of all factors involved in production. This department should be in every firm for preventing errors before the product reaches the hands of the customer.

Functions: This help to check the quality of each product. It is also helps to find damaged product before delivering the product. Every employee is expected to take responsibility for managing quality issues in order to make sure that waste is minimized and quality maximized.

AWARDS OF THE COMPANY

Best implementation award in 5s technique. ISO 9001:2000 certified award in the year 1990. Quality implementing has started in the year 1994. TPM is implemented in the company.

SWOT ANALYSIS
The SWOT analysis is an extremely useful tool for understanding and decision-making for all sorts of situations in business and organizations. It is a strategic planning method used to evaluate the Strengths, Weaknesses, Opportunities, and Threats involved in a project or in a business venture.

STRENGTH: 1. Effective management.

2. Quality of production. 3. Products are well accepted in the market. 4. Satisfactory organizational set-up with experienced and well-qualified employees. 5. Experienced promoters in the industry WEEKNESS:

1. Lack of transportation. 2. Lack of infrastructure.

OPPORTUNITY:

1. Increasing demand of yarn for local oriented production. 2. New customers. THREATS:

1. Competition in domestic market 2. Changes in Government policy regarding taxation and related matter. 3. No government support for textile industry.

FINDINGS

In company the quality of the product is main source of the organization. The organization and the employers are having the good coordination between them. In the company the canteen facilities are very bad; there is no hygienic food in the environment. The transport facilities are not available to the employees frequently.

 In the company all the employees have should follow the regular uniform.

SUGGESTIONS AND RECOMMENDATION

CONCLUSION

ANNUXURE