Professional Documents
Culture Documents
Friction-tapes
Fabrics
Furniture covers
Hand kerchiefs
Hosiery
Lace
Mosquito-curtains
Paper
Safety bags
Sheetings
Shirts
Shoe-laces
Tapes
Terry-cloth
Threads
Tickings
Tobaco-cloth
Towelling
Typewriter-ribbons
Tyres
Umbrella-cloth
Wall-coverings
Washing cloth
yarns
Millions in the world are directly dependent on this king fibre and the
vagaries of this king (Flutuations in prices) wither make or mar millionsmaking them wither rich or poor and generally causing immense ups and
downs.
As stated cotton is a king-fibre, but it is an arrogant king. It assumes
that its virtues being so great no further skill be exercised. Of course there
can be no doubt that cotton has enjoyed this unchallenged position, for
cotton is a fibre with rugged virtues and unlimited hitherto unseen
possibilities. And more qualities are added as research progress further.
In recent years, however, cotton had suddenly relized that there are
other competitors for the crown. These seems to be a general rising against it
and also there are
positive and hostile signs of rebllion. In fact, its crown has already tumbled
down and part of its empire has already gone. Competitors are proving to be
a rather tough problem and very severe headache for this king.
Many different fibres are competing with this king-fibre and among
these are silk and wool which offer competition on the finer side while
enough other fibres like linen, hemp, sisal and ramie offer competition on
the tougher side. But a more serious competition on the tougher side. But a
more serious competition comes from man-made fibres like rayon (made by
processing a natural substance and then reforming it ) and more recently
from synthetic fibres (made entirely fromchemicals produced by man like
nylon and terylene.
Theses man-made fibres are made from substances which are
negligible in price and therefore their competition is going to prove vital or
almost fatal to this king.
The common textiles fibres may be classified as shown in table 1.2
Cellulose
Natural
Manufactured
Flax (stems)
Viscose
Ramie (Stems)
Cuprammonium
Jute (stems)
High-tenacity rayons
Hemp (stems)
Sunn (stems)
Sesal
Coir
Natural
Manufacured
Wool (sheep)
Protein
Mohair (angora
Goat)
Cashmere
and
Acetate (cellulose
Ester)
Nylon (polymide)
Thermoplastics
Dacron (polyester)
Orlon (Acrylic)
Vinyon
Natural
Manufactured
Rubber
Mineral
Asbestos
Alginates
Fibreglass
Paper
Metallics
As can be seen from table 1.2 there are a wide variety of fibres
available. Each kind of fibre has its own particular properties and
advantages. For example, wool is warm and resists creasing because it has
natural elasticity. Silk is soft and lustrous. Linen is crisp and shiny. Synthetic
fibres are very strong and absorb little water.
Hence, if this arrogant king just forgets the glory of the past and tries
to adjust itself to the changing environment, it may still holds its place as not
king but leader of the fibres, and may at least retain (if not regain) its losing
empire, for Cotton is a fibre with rugged virtues.
THE RISE OF THE TEXTILE INDUSTRY
Thousands of years ago, man lived in caves and spend his life hunting.
The only cloths he had were the skins of the animals he killed. Then he
discovered that he could twist together wool and plant fibres into yarn (that
is spin)
And interlace the yarn into cloth (that is weave). The word textile is
derived from the Latin term textiles for woven fabrics. Thus by textiles we
understand those objects which have been prepared by weaving.
A far back as 500 BC, Egyptians and other ancient people were
weaving fine linen and wollen cloth. In about 3000 BC, the Chinese
discovered how to weave beautiful cloth from the delicate threads spun by
the silkworm. The Indians began making cotton cloth very soon after wards.
Spinning and weaving were done by hand at home until the 1700s.
Then the invention of machines such as the spinning jenny, the spinning
mule, and the power loom led to the development of textile making as a
large-scale industry. People left their homes to spin and weave in factories.
The discovery of synthetic dyes and artificial silk in the 1800s and synthetic
fibres in the 1900s gave textile manufactures a much wider range of
materials to work with. Today, we can buy brightly coloured fabrics which
do not crease
or shrink, which dry quickly, and which do not need ironing. They
may contain fibres made from glass, coal, oil or even rock.
COTTON TEXITLE INDUSTRY IN INDIA
Indians cotton textile industry occupies a unique position. It accounts
for about 7 percent of the gross domestic product, 20 percent of the
industrial out put, and over 30 percent of the export earnings. It contributes
over Rs. Five. Billion in terms of excise duty to the exchequer. After
agriculture, this industry is the second-largest employment provider in the
country as its cultivation provides 200 man days/hectare of employment.
Around 60 million people earn their livelihood through its cultivation or
trade and processing. A considerable number of people also get benefited
through its indirect employment.
At the time of independence, the textile industry, the largest organized
industry in the country, comprised an estimated 2.5 million handloom
weavers and 356 mills, with an installed capacity of about 10.3 million
spindles, 2,00,000 looms and 7,00,000 workers. After that, the increase in
fabric production is mainly because of the availability of major raw
materials, such as cotton and man-made fibres. However, the share of cotton
gradually declined from 99 percent in the fifties to 69 percent in 1997. As an
aftermath of partition of the country, 30 percent of cotton-growing area went
of Pakistan. But through concerted efforts, the country could achieve selfsufficiency.
SIGNIFICANT CHANGES
From the mid-eighties on wards the cotton textile mill segment has been
experiencing significant changes caused by market resurgences, mill
reconstruction, deregulation and economic reforms
In recent years, the market for cotton cloth grew rapidly athe average
rate of profit and value added per worker improved. Over the years, the
fibre-mix pattern of cloth has also undergone change. In the fifties cloth was
mainly cotton-based but now cotton cloth accounts for only to percent of the
total production. The remaining 40 percent is contributed by blented and
cent percent non-cotton cloth. Of course, there has been an improvement in
the quality of fabrics.
At present, there are 1824 textile mills in India, out of which 1543 are
spinning mills and the remaining 281 composite mills, i.e. in the postindependence period. There has been nearly a five fold increase in the
number of cotton / manmade textile mills, within a period of around 50
years.
COTTON AVAILABILITY
Cotton is the main raw material for the cotton textile industry. Availability
and its price level will have a bearing on the performance of the cotton
textile industry. Cotton is the most important commercial crop in India,
occupying 92.61 lakh hectares of cultivated area. It accounts for 28 percent
area in worlds total cotton cultivation area, which is the largest in the world.
COTTON PRODUCTION
India is the third largest producer of cotton after china and USA. Cotton is
grown over around 22 milion acres, with a production of 2.7 million tones a
year. Sowing begins in May some areas and picks up in june with the arrival
of monsoon. Indias production of cotton was 26,35,000 tonnes in 1999,
which was 14 percent of would
production. But yields per hectare here are the lowest among the important
cotton producing countries in the world.
Currently China, USA, Russia, India, Pakisthan and Brazil are the first six
major producers of cotton in the world. When world cotton production
increased by 5.26 percent from 1985 to 14 percent in 1999, in the same
period cotton production of cotton increased from 13 percent in 1985 to 14
percent in 1999.
PROBLEMS FACED BY INDIAN TEXILE INDUSTRY
There is a general belief that India is becoming uncompetitive in
manufacturing cost due to a variety of factors arising mainly from increasing
input costs. In a fiercely competitive world market, an essential condition for
survival is to maintain the cost of manufacturing at an international level.
Realizing this disturbing trend, the cotton textiles export promotion council
(Texprocil) commissioned a study on benchmarking of costs of production
in India vis--vis China, Pakisthan, Indonesia, Bangladesh and Sreelanka by
appointing a professional agency, Ms. Gherzi Textile organization, Zurich,
Switzerland. The finding of the study reaffirm that India remains uncompetitive to the extent of around 15% when compared to the cost of
competing counries.
The key findings of the study indicate the following:1) Highest power cost:- Power is one of the major factor costs as it
contributes around 20 percent of the total spinning cost and 10 percent of the
production cost of fabrics. India ranks amongst the highest in power and fuel
cost. While power cost average 8.87 US cents per kwh in India, it is 3.49US
cents in Bangladesh, 3.65 cents in Indonesia, 6.04 cents in China and 6.57
cents in Pakisthan. Similarly the cost of fuel in India is US cents 1.96 per kg
of steam. It is 0.78 in Bangladesh, 0.58 in China and 1.41 in Pakisthan.
2) High raw material cost:- As regards the raw material, cotton yield per
hectare in India is the lowest of 302 kgs/hectars as compared to the world
average of 538 kgs/hector. Against this, Chainas yield is 1028 kgs/hectare
and Pakisthans 620 kgs/hector. In addition exporting units in these countries
also get the entire duties rebated for export production. Indias lower yield
and realization, results in higher cost. Percentage of raw material costs is the
highest in total cost production here is an example.
Cotton cost is 75% of the total cost and therefore the key cost driver.
3) Low Technology:- At the level of technology while India has installed
11,161, shuttle less looms, China has 84,218 and Pakisthan has 16,867. The
share of shuttle less looms in India is 0.62 percent while it is 9.96 percent in
Bangladesh 9.3 percent in China and 6.15 percent in Pakistan.
4) Export Related Problems:- In India apart from high transaction costs the
taxation structure and labour laws are are keeping the clothing exports down.
The clothing unit with a turn over of less than 30 lakhs gets tax exemption
resulting in fragmentation of units which also affects economics of scale.
The other factor which is keeping the clothing exports from India down is
high excise duty on man made fibres. It makes blended clothing exports
(where China again is doing very well). Uncompetitive in the international
market.
World trade in clothing is a seasonal business but labour laws in India
do not allow units to hire people for a short period. No big garment exporter
is willing to expand beyond a certain limit. There are even cases where
garment manufactures have rejected big deals as after execution of the order,
they would be left with a hung work force on their payroll with no work to
employ them.
Thus with raw materials, power costs, cost of money etc. being the
key cost drivers managing them effectively holds the key to becoming cost
In Kerala, there are 31 established textiles and out of that 17 mills are
owned by central and state government, and balance are private owned mills.
Out of that 7 mills are situated in Thrissur district. Those mills are as
follows:(a) Kerala Lakshmi Textiles Ltd(Central government undertaking)
(b) Vanaja Textiles Ltd, Kunchikara(under lockout)
(c) Sitaram Textiles Ltd(Government undertaking)
(d) Rajgopal Textiles Ltd(Private undertaking)
(e) Co-Operative Spinning Mills Ltd.(Co-Operative)
(f) Thanikkudam Bhagavathi Spinning Mills Ltd(under lockout)
(g) Alagappa Textiles Ltd.(Central government oundertaking)
Through Kerala has a number of cotton textile mills, the raw material
ie, cotton is not widely cultivated here. It is either obtained from other states
or imported from outside India. The climatic conditions of Kerala frequently
change, so suitable arrangements are made in the factories to maintain the
desired atmospheric condition for the production of yarn. A large number of
people get direct employment in the mills and ever a larger number get
indirect employment. More than 20,000 workers are working in different
cotton textile mills in Kerala.
subsidiary
No
1
16
Banglore
NewDelhi
NTC (Gujarat)ltd
10
Ahmadabad
10
Ahmadbad
NTC(North Maharashtra)ltd
Indore
NTC(South Maharashtra)ltd
11
Mumbai
17
Coimbatore
NTC(Uttarpradesh)ltd
11
Kanpur
21
Kolkata
10
12
Mumbai
total
129
COMPANY PROFILE
1974. The
management of the mills vested with National Textile Corporation Ltd, NewDelhi(A
govt. of India undertaking) and later with effect from 1-4-1974 it was transferred to
its subsidiary company National Textile Corporation
(Andra Pradesh,Karnataka,Kerala,and Mahe)limited Banglore.
After nationalization consequent to the implementation of modernization/expansion
scheme the installed capacity was raised to 41328 spindles by 1985. Presently the
mill is manufacturing blended yarn in the following counts such as 45sPV, 60Spc,
and 62 PC. The main raw material polyester fibre is procured from M/S reliance
industries ltd, and M/S Grasim Industries ltd,Coimbathore. The raw cotton is
mainly purchased
from Cotton
Corporation
CAPACITY
The licensed capacity is 41,520 spindles the installed and commissioned capacity of
the mills is 41,328
REGISTERED OFFICE
National Textiles Corporation 9AP,K,K&M
ADMINISTRATION
The chief of the organization is the general managers who is a technically qualified
person having sound knowledge and valuable experience in running many textile
mills. The persons managing the various departments working under him are also
personally qualified in their respective fields. Such
as accounting
labour
either branch or bale. One bale contains 18 kg of cotton. The major suppliers of
inputs are
1. Grasim industries kumarapatnam - viscfose staple fibre(input name)
Karnataka state
2. reliance industries ltd, J R FOODS ltd Polyester staple fibre
Campus thirubhyvanan
Pondicheri
3. Indo Rama synthetic (p) Ltd nagpur - polyester staple
PRODUCT PROFILE
We present a broad range of yarn that is an ideal mixture of linen and cotton
yarn providing more strength and durability. Our linen cotton blended
yarns are perfect for machines that are widely used in textile industry.
BASIC TERMS
BALE :- A bundle or package of merchandise especially cotton, wool etc.
packed in a cover or fastened with a band or string or metal for transporting
Goods, the weight and capacity varying with the various goods. Cotton bales
are usually 181.44 Kg.
COUNT (OR YARN NUMBER) :- Count is the basic unit used to
differenctiate varieties of yarn. Counts are determined by the number of
hanks per pound. Unit being 840 yards. If the count increase thickness of
yarn decreases.
HANK : - A coiled or spun skein a loop of strings. Yarns are reeled into
hanks of preparing or finishing process.
SLIVER :- A continuous strand of loose untwisted wool or other fibres.
RING FRAME : - It is the machine for spinning. In this mill there are 47
ring frames.
SPINDLE :- Spindle is a part of the spinning machine which is used to wind
yarns. The capacity of a mill is usually expressed in terms of number of
spindles in the mill.
LAP :- lap is a continuous fleecy sheet of cotton fibres which is the output of
blowroom. This lap of cotton of usually 40 meters is then fed into the
carding machine for further processing.
SPINDLE SPEED : - The speed with which the spindle is rotating. It will
be measured in terms of Rotation per minutes (RPM).
PERSONNEL DEPARTMENT
An organization is a human grouping in which work is done for the
accomplishment of some special goals or mission. To look after the various
functions set for the organization, adequate resources in men and materials
have to be arranged by individuals who serves as managers or supervisors
within the organization. Such people have to make things happen in the
achievement of organizational objectives. With out human effort an
organization cannot accomplish their objectives.
So in order to handle precious human resource Kerala Lakshmi Mill
maintaining a personal department.
FUNCTIONS
Recruitment
Recruitment forms the first stage in the process, which continues with
selection and ceases with the placement of the candidate. Recruiting is the
disciver4ing of potential applicants for actual or anticipated organizational
vacancies.
KERALA LAKSHMI MILLS Ltd has its own policy for recruitment.
It makes use of both internal and external sources for recruiting its
personnel. Advertising in newspaper and magazine is the most commonly
used method of recruiting. It also recruits from among its existing
employees. Whenever any vacancy occurs, somebody from within the
organization is upgraded, transferred, promoted or sometimes demoted.
Minimum qualification required for selection is 10 th standard pass.
Recruitment of workers is done on the basis of skill test and physical test.
Then an interview and final interview is conducted.
The worker who is selected at first is selected as leaner, after 6 months
he is promoted as senior learner. If the work of senior leaner is up to
standard he is appointed as the permanent employee of the organization.
In staff recruitment interviews are conducted by heads of respective
departments. Then they join as trainee and are required to submit a training
report to head of respective department.
Attendance Procedure
For managerial staff, duty timings are 10 A.M to 5 P.M about which they
are very particular. Even if a staff member is 5 mins. Late in the morning
with out any specific reason, he is marked for half-day leave. Workers are
doing their work in three shifts of 8 hours each. The staff of each
employee goes on changing every month.
ESI Scheme
The main objective of Employees State Insurance Scheme is
employee welfare. It comes under the provision of employees state
insurance act 1948. employees are
Trade Union
A Trade Union is any combination of persons whether temporary or
permanent, primarily for the purpose of regulating the relations between
workers and employees or between workers & workers for imposing
restrictive conditions on the conduct of any trade or business and
includes the federation of two or more Trade Unions. In Kerala Lakshmi
Mills Ltd main trade unions are INTUC and CITU. These trade unions
are creating such an environment in the organization, which maintains
good relationship between workers & management.
Bus facilities is arranged to the workers for coming to and going from the
company.
Leave Rules
More than 3 casual leaves at a time or in a month are not allowed. Casual
leaves lapse if not utilized.
b) Sick Leave
SECURITY DEPARTMENT
PRODUCTION DEPARTMENT
Production concepts are one of the oldest concepts in marketing
production concept holds that consumers will favor those products that are
widely available and at low cost. Managers of production efficiency and
mass production.
The assumption that consumers are primarily interested in product
availability and low price holds in at last two situation. The first is, where
the demand for a product exceeds supply in developing then in its fine
points, and supplies will concentrate on finding ways to increase
production.
Second situation is where the products with high cost and has to be
decreased to expand the market . Texas instrument (IT) is one of the leading
U.S. exponents of the Get- out production , cut the price.
MEANING:
Converting Raw Material into finished goods Indicates production.
Production is a process of carrying required raw materials to shape into
required finished products.
Definition
According to Edwin . S. Buffa production management deals with
the decision making related to production process , so that the resulting
goods and services are produced according to specification in amouts and by
the schedule demand and at minimum cost.
Scope Of Production :
In early stages the stress was on controlling the labour costs
because labour cost was the major element of the total cost of production
Earlier periods there was no mechanization of production
system like the one they have nows. It was too old tradition compared to
this new millennium. The process of mechanization was slowly improved
step by step.
Production Planning
Quality control
Inventory control
Work Measurement
Production Control
Method analysis
Plant layout
Material handling
Other functions
Price
Cotton
170 kg
Rs 46 to 56
Polyester
380 kgs 466 kgs
Rs 70
Staple fibre
Viscos staple 250 kgs and 252 kgs Rs 74
fibre
2. Raw material consumption per day mill
a) cotton
b)psf
c)vsf
- 10 bales
- 12 bales
- 3 bales
PRODUCTION PROCESS
Production process
Mixing
BLOW ROOM
CARDING
DARNING
ROWING
SPINNING
COINING
PACKING
SPINNING DEPARTMENT
In this department the raw material cotton is converted into yarn. This
department consists of 110 to 120 workers in 3 shifts.
Raw material cotton comes in pressed bales. Cotton is usually
measured in mounds (37.32456 K.G) and candies (355.69772 K.G). there
are different varieties of cotton like H4, H6, H420, Sankar-6 , Sankar-4,
mcu5. Out of these varieties mcu5 is the better quality. All other varieties are
inferior compared to this.
In order to get a better quality yarn two or three qualities of cotton are
mixed together.
1 bale = 160 KGS. Every day this company is using 30 bales of cotton
and converts it into yarn. In this department the process starts with the
mixing of different varieties of cotton
Cotton processing process
Bail
Mixing
Raw cotton contains several impurities like rope , hair, plastic, seeds, stones,
bird feathers, wood pieces, paper pieces etc. all these unnecessary particles
are to be removed from cotton to get quality yarn.
For mixing cotton layering is done. Different varieties are laid in
layers in proper mixing ratio. Then water is sprayed on each layer. The
layers are then cut vertically and taken into blow room & put into mixing
bins.
All these activities are carried out under 65 degree and 70degree
Relative humidity. This humidity is maintained by machines, which sprays
water.
There are 3 mixing bins where the mixed cotton is placed. Inside these
bins 2 atomizer fans which sprays water to moisten cotton. Details of mixing
are written outside the bin. If the mixing is not properly done, then iusre
effect is observed in the knitted fabric. From the mixing bin the cotton is
again cut vertically and enters the blow room line.
Axiflow
Multimixer
Astra
Unit Feed 1
Step Cleaner
RN beater
Unit Feed 2
RSK beater
Partial cleaning is done at each of these stages. These contain two
wheel like structure with nail like protrusions. Fast blow air is passed
through the entire system. Therefore the cotton moves ahead and the seeds
fall below. These are wastes or droppings. Magnets are also attached
somewhere in the pipe to attract iron impurities.
1. GBR :
by a conveyer belt which is beefed up here and thus seeds and other
impurities are removed by grid bars.
2. AXIFLOW COMPARTMENT: This is fitted with beaters.
Cotton moves from GBR to axiflow by suction and impurities fall below in a
bin under the gravitational pull. If the temperature of cotton increases
beyond a limit, it is automatically expelled from the feeder to water tank
through a pipe. Cotton is blended here so as to produce the uniform quality.
3. MPM:
Production Manager
Maintenance
Shift In charge
There is one attendar for entire blow room line. His duty is too take
the cotton from bin put it on GBR lattice. Secondary he removes the blow
room waste every 2 hours and puts in a sack kept there.
Blow room cotton goes to the carding machines, which is the first
stage of spinning.
Spinning Sequence
Carding
SLYVER LAP
DRAW FRAME
RING FRAME
AUTO CONER
1. CARDING
Blow room cotton goes into the card machine and comes out in the shape
of slyver. Final cleaning of cotton occurs during carding. There are three
types of waste, which come out of card:
a). Dropping: This comes out through a similar procedure as in beater
Total waste received is 2 %
b). Fan Waste: Fan pulls the short fibers and the cotton moves ahead.
Total fan waste received is 05%.
c). Flat waste: Flat waste is combed out as short fibers and rolled over a
cylinder. Its speed is 8.5% inch per minute. Total Waste 1.5%. the purpose of
carding machine is parallelisation, opening and cleaning of cotton.
Auto lever is attached to card machine which checks count. If the
count differs from the required amount, it shuts the machine. Cotton comes
out of the machine in a web. All the web pass through cylinders to form
slyver.
2. Slyver Lap
Here slyver is transformed into laps. The main function here is of
blending. 17 slyver combine to give 1 lap. Therefore the blending is 1/17.
1 lap = 180
Wt. Of lap = 60 gm per meter
3.
Draw Frame
This is the final stage of bending. Here blending and fibre
parallelisation occurs. The process is done twice to get perfect blending.
8 slyver on one side and 8 on the other side are mixed to get two slyvers
in the end. There fore blending is 8 times.
Speed is 300 meter per minute
1 can = 3000 meters
4.Ring Frame
Here twist is given to the yarn to give it the proper shape. Different
1.917%
2.3227%
Fan Waste
1.109%
Usable Waste
Slyver waste
PACKAGING
All the cones are stored in a room where an automizer fan supplies
moisture. This is done to provide strength to the yard and also to increase the
weight of cone. These cones are checked for their weight, quality, count etc.
These cones have different colours indicating different counts. Then a
sticker is placed inside the cone which contains information about count,
cone weight, date, Number & the person who inspected etc. Each cone is
then put in a polythene bag and then placed in carton.
1 carton = 24 cones
Total wt. Of the carton = 50 kgs
Average production in 24 hours = 4000kgs
The humidity plant
Kerala Lakshmi mill contains a humidity plant which controls the humidity
with in spinning section. If the humidity increases lapping occurs on the
cots, which are present in the ring frame. If it decreases breakage of yearn
occurs. Cotton strength increases with moisture gain. This plant contains
massive underground set up and huge fans on the rooftop. Air from outside
is taken into the unit and the air in the unit is thrown out.
PROCESSING DEPARTMENT
1.Laboratory
2.Processing Plant
3.Finishing department
4.total quality Control
the basic reactive dyes. A sample fabric is dyed, certain tests are
performed on it and is send to the buyer for approval.
Apart from this, every Chemical which is coming in the department is
checked and shade marching is done. The laboratory is provided with the
following instruments.
1. Dyeing Machines:
There are six semi automatic and two fully automatic dyeing machines
are there. The sample taken for this type of dyeing is about 10gms. The
fabric is dyed here and its quality is checked.
2. Colour Tester
It check if the colour dyed is as demeaned. Checking shade and tone of
the colour.
3. Washing Machine
4. Oven:
The oven dries the wet fabric. No sunlight is used for drying purpose.
5. Weight Box
Used for weighting colour. Weights range from milligrams to a few
grams. Both manual and electronic weighting instruments are used fro
the measurement of weight of cloth and colour.
Various tests performed in the lab.:
2. Shrinkage Test:
a. Hel test
b. H2O2 Test
c. Acetic Acid Test
d. Caustic Soda Test
e. Salt Test
f. Soda Test
g. Softener Test
h. Husk Test
Hardness of Boiler water and its ppm is checked.
6. Light fastness Test:
It is measuring fastness of color in the sunlight. In lab, a cloth is placed
under mercury lamp for 24 hours and then color of the cloth under test is
compared with the standard one.
7. Precipitation Test:
PH of the dye on the cloth is measured whether is it alkali or acidic
2. Processing Plant:
This unit performs job processing that is dyeing, bleaching and
finishing of the grey fabric brought to the company. In this plant .55
standard dyes are used as the carrying capacity of the fabric is only 4% to
10%. Standard dyes are used in dark colours but they fade with the time
due to the low retaining nature of cotton.
DYEING FLOW CHART
Grey Fabric
White
Fabric
(Bleaching)
Washing
Salt (NaCI)
[for Exhausting extra colour]
Soda (Na2NaCI)
Washing
Chemicals
time 30 minutes
Fabric Washing
To wash off extra Colour
Softner
To Soften the cloth
MECHANISM
1. Lot Making:
As the fabric is shifted from the stores to the lot making section, lots of
the fabric is made depending on the machine size. Reversing of the fabric
is done to enable uniform dyeing and to cover dyeing and to cover dyeing
defects.
2. Pretreatment
before dyeing, the fabric is pretreated so as to make it more respective to
the dye and increase colour fastness. Pretreatment of dye involves simple
bleaching, removal of dirt stains. NaOH is added which increases the dye
affinity, absorbency, Iusturee and Strength of the fabric.
2. Processing:
In the processing plant dyeing, bleaching, finishing etc. of the grey fabric
is conducted.
a) Bleaching:
The grey fabric is treated with caustic and H2O2, which bleach the
fabric, and the result is white fabric for dyeing after washing.
b). Dyeing:
It involves the colouring of fabric in either non-white, white or super
white colours. There are separate machines for non-white or super white
colours. The dye used in the colouring of the fabric makes up a small
percentage of the total wt. Of the contents of the dyeing machine.
c). Drying:
Drying of the dyed fabric is based on two principles:
1. Centrifugal Action
2. Ballooning action
The centrifugal action concept is used in older machines like the Heliot
mini Hydro Extractor. In the second concept, the fabric is steam dried on
two different machines to enable total drying.
In the first kind of machine, the fabric is steamed by blowing steam into
the stretched fabric which is rolled on a cylinder. In the other machine the
fabric is held by the workers while the mechanical action of the machine
pulls the fabric while simultaneously spraying it with jet of steam.
Drying is followed by tumbling which enables further drying and
shrinkage control. Calendaring of the tumble dried fabric is done. The
calendaring can either be done on flat or rolling or on both the machines.
A single machine can also have a combination of both types of
calendaring. Garment washing is done next which is followed or in some
cases preceded by steam ironing of fabric.
Process flow Chart
Stores (Fabric)
Lot Making
Dyeing
Drying
Finishing
Checking / Packing
Dispatch
3. FINISHING DEPARTMENT
finishing is the last stage. The machines are used for hydro extraction,
drying calendaring pressing and folding. Some important machine work is as
follows:
3. Fongs Drier
Four cylindrical dryers dry with the help of steam. The wet cloth must be
round in shape. Cloth is dried while loading as well as unloading and the
calendaring is done by controlling the pressure of hot steam.
4. Bitexmaa Caendar:
This machine is used for diameter adjustment and automatic pressing of
the cloth.
5. Heliot Calender
For diameter adjustment, pressing and making rolls of cloth. The colors
and cuffs are dried in the tumblers and then are detached from one
another by the workers.
6. TOTAL QUALITY CONTROL
Quality control is the most important department and its proper
functioning is very important for the unit to maintain high standards of
quality because the fabric passes through a number of machines where it
may get defective. It takes care of following factors:
1. Shrinkage:
Actually, before staring dyeing, it is calculated that how much shrinkage
in the fabric is expected. For this 10 gm fabric is first measured and then is
send for dyeing and finishing and after that its length, breadth is again
measured. The difference in these two measures is known as shrinkage.
Shrinkage up to 8% is allowed.
2. Washing fastness:
For drying to be good quality, it is very important that it should have
good washing fastness.
3. Dying Luster:
It is seen most of time that the fabric losses its luster after sometimes. It
is job of quality control department to check that drying luster is of good
quality.
4. Soda Patches:
While dyeing due to sodas addition, strains of soda occur on the fabric.
It is important to remove these strains before passing the fabric to finishing
department by using various chemicals.
5. Flap defect or Tailing:
It is responsible for uneven dyeing where in more colour is absorbed near
flaps.
6. Streaks:
His defect causes colour strains of dye in the fabric near the folds.
7. Oil Stains
Stains are caused accidentally on the fabric while working on particular
machine or during the transfer of fabric between machines.
FINANCIAL DEPARTMENT
The finance in the modern business world is the life blood of the
business economy. We can not imagine a business without finance because it
is central point of all business activities.
The resource including financial resources of every organization, as
economist admit, are always scares and therefore, require proper planning
and control in order to achieve the best out of funds available.
FUNCTIONS OF FINANCIAL MANAGEMENT
OBJECTIVES:
Maximization of profit is generally regarded as a main
objective of a business enterprise.
Wealth maximization
Success of promotion depends on financial administration
Smooth running of an enterprise depends upon second financial
planning.
Finance administration coordinates various financial activities.
Profit citify is the focal point of decision making
It is a determinant of business success
MARKETING
Marketing:
Def: - Marketing is a societal process by which individuals and groups
obtain what they need and want through creating, offering and freely
exchanging product and services of value with others.
Marketing concept is a business philosophy that challenges the three
concepts we just discussed.
Marketing concept holds that the key to achieving organizational
goals consists of being more effective than competitors is integrating
marketing activities towards determining and studying the needs and wants
of target markets.
SELLING CONCEPTS:
It holds the consumers, if left alone, will ordinarily not buy enough of
the organizational products. The organization must therefore undertake an
aggressive selling and promotion effort. The concept assumes that
consumers typically show buying inertia or resistance and must be waxed in
to buying.
SWOT ANALYSIS
Strengths
Presence of highly technically qualified executives
Company and its workers are strongly committed to quality
Fully and semi automated production system
WEAKNESS
Employee morale at lower level is only moderate
Less efforts to motivate employees
Less delegation of authority to department heads
Less initiative is planning of activities and coordination of work
OPPORTUNITES
The company can make use of the existing facilities more
productively
SUGGESSIONS
1. It is common suggestion that salary and wage system of employee
should be increased to improve the satisfaction level of employees.
2. Installation of additional machinery or man power will help to reduce
the work load of employees.
3. It is advisable that training and development programme can be give
to employees in order to increase their efficiency.
4. Company can provide job security so it will help to increase the
employee morale.
5. Work force should be utilized to the maximum possible extend to
make the company profitable.
CONCLUSION
Kerala Lakshmi mills is a name that stands for quality of textiles. This
company is mainly producing cotton silks.
Increasing the frequency of advertisement on mass media will
improve the products awareness among the public.
The commitment and efficiency of employees helped Kerala Lakshmi
Mill in capturing highly competitive market. Product quality enables the
organization to get the prominent place among the corporate entities.