A REPORT ON

NIKUNJ SILK MILLS

TO STUDY APPLICATION
OF
PRODUCTION MANAGEMENT

DONE AT

NIKUNJ SILK MILLS

SUBMITTED BY: SUBMITTED TO:

PATEL GHANSHYAM (62) Miss JAGRUTI MADAM

PATEL GIRISH (64) (Lecturer)
RAJPUT GITESH (81)
SHAH AMAN (90)
TRIVEDI SAGAR (111)

Bhagwan Mahavir College

of
Business Administration

Vesu, Surat
 DECLARATION

We all members of the group-2, Ghanshyam, Girish, Gitesh, Aman,

Sagar clear that this report is originally created from NIKUNJ SILK MILLS.

It is not copied from any other material and also we declare that it is
made by us with the mutual help of each other.

DATE: _______________ __________________

Patel Ghanshyam
PLACE: ______________ __________________
Patel Girish
__________________
Rajput Gitesh
__________________
Shah Aman
__________________
Trivedi Sagar

2
 EXECUTIVE SUMMARY

In this report, We have included the Plant Layout, Production Process

, Material Handling System, Inventory and Quality Control of the NIKUNJ
SILK MILLS, a textile mill which produces DRESS MATRIAL and SAREE
MATERIAL and sells its products in the local market of Surat.

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 Index

No. Topic Page No.

1. Confirmation Letter 5
2. Introduction 6
3. Plant Layout 7
4. Manufacturing Process 11
- Graphical Presentation 12
- Winding Machine 15
- T.F.O. Machine 16
- Warping Machine 18
- Passing 19
- Bobbin Machine 20
- Power Looms 21
- Mending & Folding 22
5. Material Handling System 24
(Equipment & classification)
6. Inventory & Quality Control 28

Date:

Nikunj Silk Mills

39, Uma Industrial Soc.,
Bhatar Road, Surat.
Mob: 9898616752

4
 I here by the owner of Nikunj Silk Mills Mr.

Ramanbhai M. Patel confirm that Girish Vishnubhai

Patel (B.B.A. student) and his friends have visited my

mills by my permission and I have given them some

information about my mill as well as given them

necessary guidance.

INTRODUCTION

Textile industry is very large industry in Gujarat which is founded by

Mr.Ramanbhai Mangaldas Patel and is situated at Uma society, Batar road,

5
Bhatar, Surat. It is one of the most dominant players of the surat textile

industry and it has a very good reputation in the textile market. The firm is

well known for its quality of goods. Nikunj Silk Mills has 120 machines

which used to produce 7000-7500 meters of cloth per day. Nikunj Silk Mills

is selling grey cloth in market high price to other firm like such as lioan is

selling Rs. 11.20 when market running price is Rs.12.40.

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 PLANT
LAYOUT

7
The first floor - 48 looms and two bobbin machines.

8
Second floor - 4 T.F.O. machines, a winding machine and a stock
department.

9
Third Floor - warping, office & ready stock.

10
Raw Material (Yarn)

11
 Winding Machine

T.F.O. Machine

Steam Machine

Bobbin Palti Warping

Machine Machine Machine

Passing

Power looms
Machine

Finish Goods (Grey

Cloth)

Brief Description of Process

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Nikunj silk mills Purchase Yarn (Raw Material) from The Kejariwal
Industries Ltd. for produce the Gray Cloth. Firstly the Yarn gets into the
Winding Machine and the yarn is converted into scopes and than the scopes
are taken to the T.F.O. Machine for convert the scopes into the rolls than
same at the rolls go to the Warping Machine for prepare the Bim and rest go
to the Bobbin Machine to convert the rolls into the Bobbin. And than the
Bim and Bobbins are taken to the Power Looms for Produce the Finished
Gray Cloth.

YARN (RAW MATERIAL)

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Nikunj Silk Mills purchase Yarn from the Kejariwal Industries Ltd. yarn
come in the form of Corn. One box carries approximately 12 or more corns
and the weight at the box is approximately 36 to 42 Kg. Nikunj Silk Mills
use first quality yarn at Kejariwal Industries Ltd. There are two types of
Yarn. One is “S” type and second is “Z” type. Nikunj Silk Mills use at
current time 80/48 denior yarn. This material is used in liyon.

Nikunj Silk Mills fills up “S” Type Yarn in Green Colour. “S” type yarn’s
thread moves in the Forward Direction. Nikunj Silk Mills fills up “Z” Type
Yarn in Red Colour. “Z” type yarn’s thread moves in the Backward
Direction.

WINDING MACHINE

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The Winding Machine use for to fill up the scope from the corns. It’s the
primary machine of the process. It takes 60 to 40 minutes to complete the fill
up the scope. It includes 96 scopes. The Winding Machine is run with the
2hp motor. In winding machine, it is working 1 day 12 times and one scope
weight is 250 to 300 gms. It’s connected with Belt & Puli. The thread is
passing from corn to Scope through guide The Scopes are taken in to T.F.O.

T.F.O. MACHINE

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T.F.O. Machine is used to fill the roles from the scopes. It has Capacity of
480 roles. It takes 30 Hrs. to complete the 480 roles. In these 480 roles 240
roles of “S” (Green) type in the upper Segment & 240 roles of “Z” (Red)
type in the lower Segment.

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In “S” type roles Gear moves to Forward Direction & “Z” type roles Gear
moves to Backward Direction. T.F.O. Machine is run in two shifts of 12 Hrs.
One worker can run 2 T.F.O. Machine Simultaneously. The worker is paid
under daily wages work of 160Rs. per Day. The Worker is paid Fortnightly.
T.F.O. Machine is run with the Help of 1.5 to 2 hp motor. The T.F.O.
Machine has 12 Section. Each Section containing 40 roles. In T.F.O.
Machine the Puli is
connected with the help of
Belt to the motor. Motor
makes the Puli run. The
motor belt is made in the
Black Rubber. This Firm
use to have a Control on
Worker. This Firm Has put
up the Clocks for every
T.F.O. Machine, which
Shows the Time for which
the Machine has work. Such as, if the machine is stop at that time clock is
Stop. So, the Supervisor Check the clock & can know about Machine how
many Hrs. the Machine as Work.

WARPING MACHINE

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Warping Machine is use to Convert Roles in to Bobbin. The Roles Are
steamed before they are taken in to the Warping Machine. The Warping
Machine has a Large “KILL” (i.e. Verticals & Horizontals Row) to put the
Roles. The “KILL” has Capacity of 560 Roles. The Beam is made in the
Section of 400 threads. So, if it has 3600 threads it will be having a Section.
The threads go to beam through the “Giant Role” which is put up between
the “KILL” & beam. Warping Machine has motor of 2 hp. The Bobbins are
put in the “KILL” row of 2 of “S” type & 2 of “Z” type.

GIANT WHEEL KILL

PASSING

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To get the beam in the “POWER LOOMS” it should be passing from the
“RAJ” (i.e. Aluminum Wires) one by one than the whole beam is taken to
the Power Looms with “RAJ”. There are 500 – 520 threads passed into
Aluminum wires.

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BOBBIN MACHINE

40 Roles are feed up in the Bobbin Machine. The Roles are converted in to
Bobbin. The Machine can Produce 40 Bobbins at a Time. It takes 25 minutes
to complete the Process. Bobbin Machine works with 2 hp motors.

POWER LOOMS

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The beam is taken to the “POWER LOOMS” with “RAJ”. To Prepare the
Finish Gray Cloth (i.e. Finish Goods) In the Power Looms, the beam threads
are passed Vertical. When bobbin thread is passed horizontally through
Shuttle, Where bobbin is already put up in the Shuttle. The Wooden Tap is
fitted with Leather Belt and Wooden Tap is pushed to shuttle. To wave the
threads are arrange on machine, one-time beam threads are UP & bobbin
threads is DOWN and second-time beam threads are DOWN & bobbin
threads is UP. The machine is run with the Electric Motor of 1 hp. The pick
up of the machine is set on the Gear Wheel. The Machine speed is
depending on the machine pickup. The machine gives 13.75 pick up with the
gear of 40 no. The capacity of the machine is 100 meters in 28 Hrs.

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 MENDING

After the Gray Cloth is

produced, the 100 meters cloth
is mended by the Supervisor. If
there is any defect in the Gray
Cloth. After assuring that there
is no defect in the Gray Cloth.

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FOLDING
After the Gray Cloth is checked by
the supervisor it’s folded on the meter
table & counting the meter of Gray
Cloth. And last they tied the Gray
Cloth with the piece of gray cloth.

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 Material
Handling
System
(Equipment & Classification)

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 This person is take collecting raw material from the
cartons and this raw material will go to the winding.

This raw material will be transfer in scopes.

All the scopes are store to a particular place.

T.F.O.
Machine
is used to
fill the
roles from
the
scopes. In the end the T.F.O.
creates 420 rolls and these rolls go
to the warping.

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 It’s a very important part of the process.
Warping Machine is use to Convert Roles
in to Bobbin. The Roles Are steamed
before they are taken in to the Warping
Machine. The Warping Machine has a
Large “KILL” (i.e. Verticals & Horizontals
Row) to put the Roles.

When the warping process completes the beams

the beam in the power looms it should be passing
from the RAJ. One by one than the whole beam is
taken to the Power Looms with RAJ.

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 This is a Bobbin Machine which
makes bobbins of Yarn.

In the Power Looms, the beam threads are passed Vertical. When bobbin
thread is passed horizontally through Shuttle, Where bobbin is already put
up in the Shuttle. The Wooden Tap is fitted
with Leather Belt and Wooden Tap is pushed
to shuttle. To wave the threads are arrange on
machine, one-time beam threads are UP &
bobbin threads is DOWN and second-time
beam threads are DOWN & bobbin threads is
UP.

The cloth is being cleaned and folded on the

meter table & counting the meter of Gray
Cloth.

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And this kind of Gray clothe is prepared
which can be sold to the market.

&
28
 The Liyon clothe which converts into dresses and saris is made from
this 80/48 denior raw material. The Kejariwal Industries Pvt. Ltd. produces
80/48 denior. Many companies like Reliance Industries Pvt. Ltd., Gokul
Industries Pvt. Ltd. etc. produces this kind of yarn. And all companies makes
deferent types of yarns like 80/48 denior yarn-Liyon, 90/34 denior yarn-
Russian.
But the raw material of Kejariwala Industries Pvt. Ltd. is better than
the other companies. This material has a unique whiteness.

• The raw material is being shifted to the lab to check how much oil is
there in the raw material. The oil level should not be more than 3 to 4
percent otherwise it causes loss to the business because the cost of the
product goes higher.

• The supervisor checks the iron balls

which should be put on the proper
place to get the perfect clothe.

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• The scopes which are ready should be put on the proper place.
• The supervisor should daily check
the machines to avoid the
unnecessary interruptions. He should
also watch the T.F.O. at the regular
period of time that yarn is not bf, the
yarn should be rolled in the proper
roll
• The material which is ready should not be
carried by dirty hands.

• In the power looms the quality control officer

(Master) takes the charge and handle the whole
workshop.

• The cloth is being cleaned and folded on the

meter table & counting the meter of Gray Cloth.
If there is some defect in the material the
worker removes it that is called Mender.

• After folding the weight

of the gray clothe is
being checked.

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• The ready stock should be put on the perfect place where it is safe.

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