Introduction of Grasim Grasim Industries Ltd is known for its world class textile manufacture.

They are a main part of the textile industry of India. They are one of the leaders in textile manufacture and are also known all over the world. Grasim believes in world class manufacturing. The 8 dimensions which they follow are: Waste (MUDA) elimination. Work environment JIT and stock reduction Total productive maintenance of equipment, operating conditions and skill levels. Quality first :SQM and best practices Customer driven: internal and external

Liaisons and understandings Information system, technology and cash flows. ABOUT BHIWANI....... BHIWANI district came into existence on July 22nd, 1972 and is named after the Administrative city Bhiwani. Bhiwani has been a prominent center of commerce since time of Mughals. Bhiwani is also known for its temples and is called as Small Khashi of India because of numerous temples. ` The erstwhile Punjab cotton Mills at Bhiwani in Haryana was taken over by Grasim Industries 1964

LOCATION

The Bhiwani District is surrounded by Hissar District on its North, some area of Jhunjunu & Churu District of Rajasthan on its west and District Rohtak on east. It is 124 Kilometer from Delhi.

GEOGRAPHY In North Region of the district there are Alluvial Plains and in South there are Semi -Desert with remnants of Aravali Range Mountains. The Soil is loom in the North region and sandy in the Southwest region of Bhiwani District. The Groundwater is mainly saline with some of small pockets of fresh water in Southwest. Total area covered by Bhiwani District is 5,099 sq.km..

Brand portfolio grasim

Brand portfolio graviea

Main Achievements & 5,S

In 1994 graviera was awarded the prestigious ISO 9002 certification. Each process form buying the fibre to finished fabric is monitored by computerized machine and highly observant works and techniques. Being a composite unit spinning, weaving and processing is done under one roof and there are strongest quality checks every stage. Again order to maintain a superior quality of the product various management practices are being carried out by the top management to give recommendation to improve the effectiveness in selected functional areas has formed management quality circiles. Good quality management procedure can prosper only in clean and sincere atmosphere and so the top management at BTM have

implemented the 5 technique which has the following meaning : What is 5,s There are 5 japanese words:SEIRI:- shorting out unnecessary items. SEITOM:- Systematically arrangement of necessary items. SEISON:- cleaning of work place and mahines. SEIKETSU:- House keeping maintaining all time. SEITSUKE:- Training and self discipline

Objectives of the company Objectives estabilish the goals and aims of business and determines shapes of future events. Objectives are the way of achieving motives for profit or social service main objectives of Bhiwani Textile Mills as given in its memorandum of association are : To introduce new products and create new markets. Increase productivity of work-force. Customer service and customer satisfaction. Improving work culture among the employees.

Increasing services.

quality

products

and

Capitalizing on company strength and use of corporate assets. continuous innovation. To provide the growth rate of about 10% per annum. Improved effectveness. To ensure that a large portion of its sales is directed towards the rural sectors and urban sectors. the advertising

Main Units of grasim Industries Viscose staple fiber Nagda(M.P) Rayon Grade Pulp Mannor (kerla) Harihar polyfibre Kumarpattam (Karnataka) Rayon Grade Caustic Soda Nagda (M.P) Vikram Cement Jawad (M.P)

Vikram Iron 7 Steel (spong iron) Maharastra Grasim Cement Raipur (M.P) Gwalior Suiting Gwalior (M.P) Graviera suiting Bhiwani (Haryana) Vikram Ispact Raigarh(M.P.) Aditya Cement Shambura Birla Consulting and Software service Mumbai Birla Telecom Ltd.

Mangalore Refiery & Mangalore Petrochemical Ltd Mangalore Vikram shipping Mumbai

Aditya Birla Group

The

aditya

birla

group business

is

among houses.

India,s

largest

Operating in the country for for over five decades and globlally means for nearly thirty years, its revenues today are in excess of US $5.6 billion,with net earning of US $ 500 million , a US $ 6 billion asset base, and a market cap of US $ 5 billion and 700000 shareholders. Its 40 state of -the -art manufacturing services, including USA, and UK. units and by sectorial 72000 Indonesia, anchored Thialand,

employees, criss-cross 16 countries Malaysia, Philippine, Egypta, Canada,

A premium conglomerate, the Aditya Birla Group is a dominant player in all of the sectors in which it operates, such as aluminiun, viscose staple fibre, copper, cement, viscose filament sponge recently, yarn, iron, branded insulaters, is apparel, power world,s chemicals, carbon black, fertilizers, telecom, financial services and more insurance.It largest producer of white cement, the largest single location refiner of palm oil, *the third largest producer of insulators, *the fifth largest producer of carbon black, *amongst the lowest cost producers of aluminium globally and *the largest fully integrated aluminium producer in India.

In India the group is the single largest producer of viscose filament yarn , gray cement (at a single location), white cement and rayon grade pulp, the only producer of linen and a leader in the ready-towear branded apparel. Grasim, Hindalco, Indian rayon, Indo Gulf and Indal most respected and from its admired stables rank among Indians top 50 corporations. The group also has a significant presence in the financial services, power sectors and with Telecommunications

strategic joint ventures with giants such as-sun life (Canada) , powered

plc (UK), AT&T (USA), The TATA Group and BPL communications LTD. respectively. In the software sector, the group is represented through PSI data system integration and software maintenance services. On the social front a value based, caring corporate, The Aditya Birla Group inherently believes in the trusteeship concept of management. Part of that make a qualitative difference to the lives of marginalized people. Carried out under the aegis of the Aditya Birla Centre for community Initative and Rural development, it is separated by smt. Rajashree Birla.

GROUP VALUE Our Values "Respect for the individual integrity, Speed simplicity Seamlessness, Self-assuredness and a 100 percent Commitment, are all values we value" Our values are non negotiable. They are never to be jettisoned For us, our values are our well spring. Our Vision To be a premium conglomerate With a clear focus at each business level. Our Mission To pursue the creation of value

For our customers, shareholders, Employees and society at large. Kumar Mangalam Birla Chairman, The Aditya Birla Group

MAIN PRODUCTS OF GRASIM 1. Viscose Fiber 2. Rayon 3. Viscose Fiber from bamboo and wood 4. Caustic Soda 5. Cement 6. Dress material of Grasim & Gwalior Suiting 7. Sponge Iron 8. Chemical Fertilizers. 9. Chemicals INTERNATIONAL FIELDS OF OPERATIONS OF THE GROUP 1. THAILAND a) Thai Rayon company Ltd., Bangkok * It produces Viscose Type Fibre. It was started in 1976. Its capacity is 61,000 tonnes per year. b) That Carbon Black Co. Ltd. Bangkok.

* This was set up in 1980. Every year 58,000 tonnes of carbon Black is produced. 2. Indonesia P.T.Indo-India Rayon, Jakarta This is the first company to produce viscose fibre in Indonesia. It was started in 1982. This company produces 61,000 to tones of fibre every year. All the machines tools and instruments are given by Grasim. 3. Philippines Indophil Textile Mills Co. Ltd. Manila. It was set up in 1975. It has 54,000 spindles of modern technology. It converts raw fibre into composite fibre. 4. Egypt Alexandria Carbon black Company. * This was set up in 1994 to produce carbon black. Grasim industries also operated in Malaysia, Singapore, Australia, England and East European Countries.

B.T.M profile Bhiwani textile mills, Bhiwani, popularly known as B.T.M was established in 1938 as a composite unit in Bhiwani with the name Punjab cotton mills. In the year 1964 the arstwhile ageing, Punjab cotton mills got a new lease of life when it was taken over by the grasim group of Industries, a prestigious group headed by honorable Sh. Aditya Vikram Birla. But after the demise of Sh. Aditya Vikram Birla it is now headed by Sh. Kumar Mangalam. In 1974 it came under the direct management of Grasim group. B.T.M is a composite mill having spinning, weaving and processing divisions. The spinning divisions where yarn is spun is having 34,576 spindles. The spinning unit is producing blended yarn of polyester &

viscose blends & pure viscose yarn. The raw material as the name suggests is polyester and viscose staple fiber The weaving unit has 120 looms producing polyester viscose blend suiting and shirting under the name graviera. Graviera is good brand name popularity in the market and is aimed at middle class segment of the society. Quality is the watch word of this unit. it is not imposed by checks and counter checks, it is a part of total manufacturing system. Quality is the first parameter. That is the reason that the Bureau of International Standards has conferred the unit with ISO-9002 certificate in 1994. Modernization, Technological upgradation and computerization is an on-going process at B.T.M. The mill has already installed 66 new donear looms from Switzerland. An

attractive feature of spinning division is Savio Auto Winding machines. one of the most sophisticated in its class. In order to keep pace with changing time and to combat foreign competition, B.T.M has stream its master plan of expansion of its spinning unit. A new unit, Elegant spinning is set up & has 14,000 to 28,000 spindles. The Research and development of the mills is famous for introducing new designs with classic colors. Some of the latest innovations in textile technology in advanced nations find a parallel acceptance in the working of B.T.M Bhiwani. Realizing the fact that human asset is the most important of all assets, B.T.M has introduced the concept of Participated

Management. There are 40 quality circles & 20 shops floor constantly engaged in improving the work culture of the mills. Keeping pace with the need of hour B.TM is becoming more and more professional in its management. The philosophy of Birla management center is the guiding spirit to move the group towards more professionalism.

SWOT ANALYSIS OF BTM Strengths of BTM :1. BTM is a reputed firm in Haryana. 2. BTM has high goodwill. 3. Working peacefully. 4. Facilities given to employees from time to time. 5. Product quality is given equally to all (Wholesalers & Retailers). Weaknesses of BTM:1. Basic salary structure is not up to date some manipulations are needed 2. Not sufficient facilities are given to employers & employees. Opportunities for BTM :environment is suitable and

1. Given chance to Grasim to make & sale its product providing them manpower, machine , money , market , material . 2. In near future they will start readymade garments. Threats to BTM :1. BTM face threats from its competitors like Vimal , OCM , Siyaram, Raymond. 2. BTM face threats in overseas market like Philippines, Malaysia, Canada, Mexico, America. 3. BTM is going to install its own thermal power station to generate electricity and local leaders are opposing and demonstrating saying about environment pollution by coal.

Manufacturing Process Bhiwani textile mills manufacturing products types yarn & fabric. The main operation involved in the production of yarn & fabric and called spinning and weaving. Here are the sub sssprocesses carried out in the executing of these operations. Carding Laps from blow room are brought to the carding machines. The main objectives of carding are opening, cleaning and silver formation of fibre. Hence, for the first time in the spinning process, the fibres are given the form of a top. silver infact are thick rope like structures of the fiber kept in big plastic drums. carding remove every impurity from fiber that had remained in it even after blowing.

Doubling Sometimes we required double yarn. this is mostly required to give some fancy effect. we can multiply 2,3 or more yarn by the process of doubling. This involves two machines-cheese winding machine and double machine. cones from winding machines are fed to the cheese winding and double machine. cones from winding machines are fed to the cheese winding and we get bobbins, on which 2 or more yarns are would in a parallel fashion. Then on doubling machine these parallel yarns are twist according to the specification. Here the bobbins again get converted into cones.

Drawing Silvers are converted into more uniform silvers. The main objective of drawing is parallalization of fibres .It increases the uniformity and evenness of the fibre. Drawing in This is the stage, where basic information takes place irrespective of the colors. These designs are called weaves & can be of various typesmat, twill, planes, double weave etc. In drawing in stage, yarn from weavers beam is drawn through healed eye and reed (two parts used on looms to produce design ) in accordance with the predetermined design for a particular fabric. Without drawing in process, it is impossible to have desired design on loom. After drawing in the beam is ready for weaving.

Dyeing and printing: Fabric can be two types according to the dyeing process: Top dyed: manufactured from already died yarn, piece/dyed: manufactured from undyed gray yarn &hence required dyeing. In the dyeing process, the polyester and viscose parts of the cloth are dyed separately because there chemicals and condition requirements vary. Polyester part is dyed by using the disperse dyes and at very high temperature. But viscous require wet dyes (i.e. the dyes which are easily soluble in water). The fabric is washed after dyeing both these parts. Fabric printing is of two types screen printing &roller printing.

After the processing for printing & or dyeing the fabric of every type is properly washed and dried. Folding The finished fabric is brought to this section for checking and folding. It is also part of quality control at BTM. The fabric is manually checked inch by inch. This inspection is done for finding any faults and removing them if removable. If faults cross a limit in certain quality, the fabric is rejected and sold under seconds. The checked cloth is folded in the form of Thans and pent length (P.L.S.) standard length of a than varies from 6 to 12 meters, pent length is a length is 1.20 meters of cloths, length of cloth lesser than P.L. are graded as- Superior - Fants : : 91cm. To1.19 mts. 45 cm. To 90 cm.

-Rags -cindi Finishing:

: :

25 cm. To 44 cm. below 25 cm.

Mended clothes are further processed in the finishing section. Finishing is one of the most important processes, because the fall, luster and drape of the final product (i.e. cloth) depends largely upon it. Some other functions that this section can perform are making the cloth fireproof, shrink- proof, wrinkle proof, water proof etc. mainly three processes are carried out in this section-processing, dyeing and printing. Loom shed (weaving): looms are the actual weaving machines. Here yarn runs in two directions-lengthwise and breadth wise. The yarn running lengthwise on

the loom is called warp and the running breadth wise is called weft. The cloth produced at this stage is called grey cloth. This is produced by inserting weft yarn in warp sheet according to predetermined design of reeds and picks. reed and picks are respectively the number of ends warpwise and weftwise in one square inch of fabric which are essential parts of looms.. Mixing and blowing The two processes are executed on the same machine Blender. The objective of mixing is to make a uniform and homogeneous blend of different types of fibres in fixed ratio. This ratio is fixed by the blend specification required in the desired final product i.e. yarn. The most demanded fibre blend is polyester/viscose in the

nation 6 6/35, 48/521,35/6 etc. mixing results I loose tufts of blending fibre, which then enter the blowing process. The main objectives of blowing process are cleaning, opening and lap formation from the tufts of fibre. Laps are nothing but long, uniform sheets of fibre wound around iron rods. Weight and length of laps are standardized. Fibre at this stage becomes free from any unwanted particle like dust stone, sand etc. Mending: The grey cloth from the loom-shed is brought for mending. The full length of the cloth is manually checked here and the defects are removed by hand scissors and other equipment. Most of the removable defects in fabric get removed here.

Processing In this subsection ,the long thread which remain loosely attached to the surface of the fabric are removed first of all. After that, small hairy fibres projecting from the surface of the fabric and certain is impurities like dust and waxy material etc. are also removed. The fabric is then thoroughly washed to remove mandi from it. It is dried then and passed on a stenter machine, where by the process of Heat set the shrinkage of cloth is removed and by chemical processing, lusture & shine are produces Packaging Each than is wrapped over a separate sheet of thick card board. Then each then is packed in a polythene bag and sent to warehouse. Pent length are sent such to warehouse(i.e. without

packing). In warehouse, the thans and P.L.S. are packed in different packages, according to the order of parties. The cloth is now ready to be transport to the dealers. Reeling Yarn can be wound in the form of hanks also in places of cones if the customer demands it so. The process of making hanks is called reeling. Bobbins from ring frame are fed to the reeling machine & we get hanks. Ring frame The roving are converted into smaller sized bobbins in this process. The main objectives of ring frames are to increase the twist and length of the roving from of fibre and thus convert it into yarn the final product. So ring frame is

the final stage in yarn production. At this stage twists are given according to the customers specifications. Due to excessive thinning, the yarn can break here. In order to avoid such breakages and unevenness in the yarn, the relative humidity is kept at about 65% in this section. Simplex The silver drums get converted into smaller roving here. The main objectives of this process are to increase the length and strength of the rope from of the fibre. This is the stage prior of spinning , twist is introduced here and thinning of the rope begins. Sizing

Sizing is a chemical treating of yarn beams the objective of sizing are: # To provide further strengh to the yarn to running on the withstand the tension while #

loom and hence reduce breakages. To protect the yarn from various type of Various material are used in sizing include-strach adhesives, fitting materials and insectiside sets. The beam after sizing is called weaver beam Spinning This is the process of conversion of fibre into yarn. fabric are two types natural and syntheic fibre. But B.T.M use of the later only. Polyester, viscose, Acrylic, Nylon, Orlon, Triolobale etc. are various sub-types of synthetic fibre, which insects.

are being used by B.T.M. The production system of yarn can be shown as: Input Output (Fibre) (Yarn) Warpping This is the first sub process in weaving. Here the yarn is used to form beams main objective of wrapping areTo form a beam To remove weal places To remove slub and fluff etc. Wrapping consists in arranging side by side, a large number of yarn ends to form a sheet of wrapped round an iron rod. This on iron rod. This sheet on iron rod is called Beam. Process (spg.) Transportation

Winding In this process yarn is wound on cones in order to get a longer and continuous yarn length, suitable for the weaving process. It also removes weak places in the yarn. The main function of winding machine therefore are to convert bobbins into cones and remove any slubs or fluffs from the yarn. Slub is a yarn defect of unevenness. Weaving Synthetic yarn is used as the input process and the end product obtained is fabric. So weaving is the process of converting yarn into fabric.

World class manufacturing As a landmark the switching over to BMC approach by its successful implementing has paved the path for policies and plans formulation incorporating the concepts of WCM. It,s motto is to BEAT THE BEST. WCM says: Practice what we preach Have you defined the QCDI of what you are going to do ?

Equipment is your livelihood, love and maintain it. WCM: The Eight Dimensions
Work Environmen t

Waste Eliminatio n

Jit& stock reduction

Information System Technology

WCM

Total predictive Maintenance

CM CREATING VALUES

Liason & Understandin g

Quality First SQM & Best Practices Custimers Driven Internal & external

HR Department Structure
President and unit head

HR head

( B.k Mohapatra )

Compensation Incharge ( Nirbhay gupta)

People processing

Incharge (Lalit dutt )

Recruitment Incgarge ( Harpreet kaur)

WCM officer
(vijay gupta)

Training Officer Spinning (Basant agarwal)

Training Officer Fabric (manohar Sharma)

Training Officer elegent (Srinath Sharma)

Compensation & salary (virender)