The Summer Internship Project Report On Organizational Overview At

BIRLA VXL LIMITED

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Submitted by KHANDHAR NILESH MBA Sem II Academic Year : 2010-2012 T.N. RAO COLLEGE RAJKOT Guided by, SHOIAB A. LOHANI

Submitted to, GANESHPRASAD SINGH SIR

EXECUTIVE SUMMARY

The textile sector is one of the fastest growing sectors in the economy. There are many players in this sector but DIGJAM is a step ahead of them all. DIGJAM is committed to satisfy customers by providing quality products and services, which give highest value for money. They believe that their employees are their most important assets through which they can reach the top in each field they venture into. ITS WHO YOU ARE they commit themselves to continuous growth so as to fulfill the aspirations of the customers, employees and shareholders. The whole project is based on understanding the two Ps of marketing i.e., Product and Promotion.

I am really very thankful to the management at DIGJAM for giving me to an opportunity to undertake a project work in their organization. I hope that the work done by me is satisfactory.

CORPORATE PORTFOLIO

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CORPORATE PROFILE
REGISTERED OFFICE:
DIGJAM Limited, Aerodrome Road, Jamnagar 361 006 Gujarat.

CORPORATE OFFICE: DIGJAM imited

801, Bhikaji Cama Bhawan 11, Bhikaji Cama Place, New Delhi 110 066, India

UK Representative Office
DIGJAM Limited 18 King shill Avenue Harrow, Middlesex HA3 8JP, United Kingdom Tel: .(44) 208 907 8687

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Fax: (44) 208 909 2527 E-mail : bvora@bvxl.com

OTHER OFFICES:
Delhi Mr. Amit Gupta DIGJAM Limited, 501, 2nd Floor, Krishna Gali,Katra Neel, Chandni Chowk New Delhi 110006

Punjab Mr. Balbir Sharma / Mr. Alok Pachauri DIGJAM Limited, 3 Kairon Market, 2nd Floor,Hall Bazar Amritsar 143006

West Bengal Mr. Ashok Bodhania / Mr. N K Sharma DIGJAM Limited, 9/1 R N Mukherjee Road Kolkata 700001

PRINCIPAL OPERATING DIVISION:

Aerodrome Road, DIGJAM LIMITED, Jamnagar 361 006 Gujarat

REGISTERED AND SHARE TRANSFER AGENTS:

MCS Limited, 77/2A, Hazra Road, 3rd & 5th Floor, Kolkata 700 029

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Tel (033) 2476 7350 54, 2454 1892 93 Fax: (033) 2454 1961, 2474 7624 e-mail: mailto:mcscal@rediffmail.com

AUDITORS:
Deloitte Haskins & Sells

BANKERS:
o UCO Bank o Bank of India o Bank of Baroda o PNB o Punjab & Sind Bank o SBI o SBS o Standard Chartered Bank o UBI

BOARD OF DIRECTORS:
o S. K. Birla Chairman o Siddharth Birla Vice Chairman o N. Lalbhai o R.K. Chaudhary o Dr. G. Goswami o Gauri Kumar o G. Momen o C. Mukherji o P. K. Pujari

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EXECUTIVES:
o C.L Rathi o M. R. Surekha o R. K. Kedia o Virendra Gupta o Ravinder Sharma o P.K. Das M. D Co. Secretary and Executive V. P (Legal) President V.P. (Exports) V.P. (Sales and Marketing) V.P. (Exports) and Business Head

STOCK EXCHANGE LISTING:

o More than 93000 shareholders listed in o BSE o NSE o Kolkata Stock Exchange o Delhi Stock Exchange o Saurashtra Kutch Stock Exchange

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MISSION & VISION OF COMPANY

MISSION
To be an enterprise acclaimed for its products & services among peers and customer alike, by having responsible workforce & through best available technology

VISION
To be the clear favorite & premium contender in our principal market.

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INDUSTRY OVERVIEW
Textile Industry in India is the second largest employment generator after agriculture. It holds significant status in India as it provides one of the most fundamental necessities of the people. Textile industry was one of the earliest industries to come into existence in India. In fact Indian textile industry is the second largest in the world, second only to China. Textile Industry is unique in the terms that it is an independent industry, from the basic requirement of raw materials to the final products, with huge value-addition at every stage of processing. Textile industry in India has vast potential for creation of employment opportunities in the agricultural, industrial, organised and decentralized sectors & rural and urban areas, particularly for women. Till the year 1985, development of textile sector in India took place in terms of general policies. In 1985, for the first time the importance of textile sector was recognized and a separate policy statement was announced with regard to development of textile sector. . 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. In the year 2000, National Textile Policy was announced. Its main objective was: To provide cloth of acceptable quality at reasonable prices for the vast majority of the population of the country, To increasingly contribute to the provision of sustainable employment and the economic growth of the nation, To compete with confidence for an increasing share of the global market.

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Various Categories 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

The Industry India textile industry is one of the leading in the world. Currently it is estimated to be around US$ 52 billion and is also projected to be around US$ 115 billion by the year 2012. The current domestic market of textile in India is expected to be increased to US$ 60 billion by 2012 from the current US$ 34.6 billion. The textile export of the country was around US$ 19.14 billion in 2006-07, which saw a stiff rise to reach US$ 22.13 in 2007-08. The share of exports is also expected to increase from 4% to 7% within 2012. Following are area, production and productivity of cotton in India during the last six decades Strengths

Vast textile production capacity Large pool of skilled and cheap work force Entrepreneurial skills Efficient multi-fiber raw material manufacturing capacity Large domestic market Enormous export potential Very low import content Flexible textile manufacturing systems

Weaknesses

Increased global competition in the post 2005 trade regime under WTO Imports of cheap textiles from other Asian neighbors Use of outdated manufacturing technology Poor supply chain management Huge unorganized and decentralized sector High production cost with respect to other Asian competitors

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Current Facts on India Textile Industry

India retained its position as worlds second highest cotton producer. Acreage under cotton reduced about 1% during 2008-09. The productivity of cotton which was growing up over the years has decreased in 2008-09. Substantial increase of Minimum Support Prices (MSPs). Cotton exports couldnt pick up owing to disparity in domestic and international cotton prices. Imports of cotton were limited to shortage in supply of Extra Long staple cottons.

Textiles Major Companies

Alok Textile Indian rayon GTN textile Centu ry textile

Arvind mill

Raym ond Sarda Textile

Major players

Digjam

Gokul das Image s

Verdh man spinni Morarj ng ee mill

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COMPANY HISTORY / INTRODUCTION

DIGJAM Limited, an S K Birla Group Company, began its activities nearly 60 years back in Jamnagar, Gujarat. Since then, it has been catering to the ever-growing demands of the Clothing and Fashion industry, in the domestic as well as the international markets. DIGJAM Limited is a leading textile company in India, manufacturer of fabrics for suiting and casual wear. In recent years, the company restructured its business portfolios to focus as a textile company manufacturing and marketing fabrics and ready-to-wear clothing under its own brands. A complete vertically integrated plant, DIGJAM has ultra modern production facilities to convert wool tops to finished fabrics through different processes of Dyeing, Spinning, Weaving and Finishing using state-of-the-art machinery imported from France, Germany, Switzerland and Italy. Stringent quality checks at every stage and process enabled DIGJAM to bag the prestigious ISO 9001 certification. Keeping pace with the complex requirements of the industry, DIGJAM expanded its production capacity to over 5 million meters, of which 35%-40% (approximately) is exported to major countries across the globe. Andersen Consulting, a leading management and corporate advisors agency, undertook a major review of the operational parameters of our textile company. Following a thorough review of the operating and marketing practices, recommendations were made which now form the basis of our strategic marketing and manufacturing thrusts spanning the coming 3-4 years. The company has also initiated steps to strengthen its organization and induct the youth and skills necessary to attain results from this strategic shift-cum-consolidation exercise. While the company lays uniform stress on all fundamental aspects such as quality, designs and costfriendliness for products under all its brands, DIGJAM is undoubtedly its premium fabrics brand. DIGJAM has a high-end fabric brand presence in the domestic market, reputed for its finish and quality. The company manufactures over 3000 design-shade combinations each year in Light Wool, Polyester Wool and Woolen fabrics for the DIGJAM brand alone. Constant research on designs ensures creation of innovative future trends. In the new millennium, DIGJAM introduced superpremium fabrics designed by European experts (with whom we work regularly and extensively) comprising fine wool yarn of Super 150s and Super 120s and occasionally blended with exotic fibers like Silk or Cashmere. Dressing in India has come of age - rising affluence levels, increased media exposure of international fashions and a growing tendency towards self-indulgence have all contributed to it. The all round impact is visible with the influx of international, and domestic products and brands in both, formal and casual wear. Indian customer has choice today, but one where we are determined to make and sustain our mark.

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The DIGJAM brand will increasingly reflect both tradition and modernity in its positioning, product range and marketing approach. We intend to position the brand as the clear favorite for a wider, but demanding clientele with special emphasis on becoming the preferred premium choice for the youthful consumer. This segment offers a high potential in terms of market size and also presents a tougher challenge to us in terms of providing satisfaction. DIGJAM'S superior product quality is at par with global standards and many of the world's best readymade brands use fabrics produced by us. A major proportion of our output is exported to USA, Europe, Middle East and Far East. This bodes well for our future as our preeminent position as one of the largest manufacturer of textiles from India. Our marketing thrust will over time impact all facets of the brand's interface with consumers, including new product introductions, consumer promotions and the rich retail experience. It must be noted that the DIGJAM brand has been ranked at no. 4 among the top Apparel brands of our country, in a study conducted by the prestigious Economic Times newspaper of the Times of India group. Apparel category comprised of all the top Fabric brands as well as the Readymade Garment brands available in the country. This particular study at the consumer level at a national level was conducted to find out India's Most Trusted Brands.' DIGJAM products and their ranges are available at its exclusive showrooms and over 3000 other retail outlets across the country.

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MANAGEMENT ORGANIZATION STRUCTURE

Board of Directors

Managing Directors

President

Vice President Export & Head universal

Vice President Technical

Vice President Sales & marketing

Vice President Legal

GM Personnel

GM Sales & Mktg.

GM Finance

Area Manager

GM Corp. Finance

Company Secretary

Chart 1: Organization Chart (1)

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DOMESTIC SALES VP (S&M) (Shri Ravinder Sharma)

East

West

South

North

SR.Manager (Shri Rajesh Sharma)

DY.GM (Shri Sharad Goel)

GM (Shri Amit Gupta)

SR.MANAGER

DY. MANAGER / ASST. MANAGER

SALES OFFICERS Chart 2: Organization Chart (2)

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SELLING REPRESENTATIVES / AGENTS DIGJAM

SRs

SALES TEAM

WHOLESALERS/ DISTRIBUTORS

EXCLUSIVE SHOWROOMS

MULTI BRAND OUTLETS

TAG DEALERS

CONSUMER Chart 3: Organization Chart (3)

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General information

1 2 3 4 5

Name of the firm Brand name Years of establishment Form of organization Location of Unit

DIGJAM LTD. DIGJAM Public Ltd. Co. DIGJAM LTD. Aerodrome road, Jamnagar. 361006 (Gujarat-India) +91(0288)2712972/73 +91(0288)2712991 mills@digjam.co.in. www.digjam.co.in 801, Bhikhaji Kama Bhavan, New Delhi110066 S.K. Birla ISO 9001 S.K. Birla (Chairman) Siddharth Birla (Vice Chairman) A.N. Lalbhai Arvind Agrawal R.K. Chaudhary Dr. G. Goswami N.L.Hamirwasia C.L. Rathi(MD) Rajiv Sharma (Executive Director & Chief Operating Officer) Kimji Kunvarji & Co., (C.A.) Mumbai. UCO Bank Bank Of India Bank Of America Bank Of Baroda Punjab National Bank State Bank Of Saurashtra Standard Chartered Bank

6 7 8 9 10 11 12 13

Tel. No. Fax No. E-mail Web site Corporate Office Promoter Certified Board O Directors

14 15

Auditor Bankers

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16

Clients

Union Bank Of India State Bank Of India Aditya Birla Nuvo Airport Authority Of India Alcock Ashdown (Gujarat) Ltd. Arvind Brands Arvind Clothing Ltd. Assam Rifles Banaras Hindu University Bharat Heavy Electronic Ltd.(BHEL) Bharat Petroleum Corp. Ltd. Birla Institute Of Technology Bombay Hospital Castrol (India) Ltd. Gujarat Alkalies & Chemicals Ltd. Gujarat Industrial Power Co. Ltd. Gujarat Narmada Valley Fertilizer Corp. Gujarat State Fertilizer Corp. Hindustan Motors Ltd. Hindustan Petroleum Corp. Ltd. ICICI Ltd. INDAL Indian Air Force Indian Aluminum Co. Ltd. Indian Farmers Fertilizers CoOp Ltd. Indian Oil Corporation (Gujarat Refinery) ITC Ltd. ICFAI Business School, Ahmadabad Mohan Clothing Company. M.S. Patel Institute Of management, M.S. University Mysore Cement ltd. NCL Naval H Q.

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Ordinance Clothing Co. Reserve Bank Of India SAIL Suarashtra Chemicals Shoppers Stop Ltd. Sports & Leisure Apparels Ltd. Taj Trade Transport Co. Ltd. Tamil Nadu Police Tata Industries Ltd. Tata Timken Ltd. Tehri Hydro Development Corp. Ltd.

17 18 19 20 21

Company Logo Production Capacity Export Import Exported Country

ITs who you are Year:- 73,00,000 Meters Day:- 20,000 Meters 50% 50% U.S.A., Canada. U. K., Europe, Middle East & Far East , Japan , Australia etc.

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DIGJAM ACHIEVERS UNLIMITED (DIACHS) CLUB

A unique and one of kind exclusive club created for the first time in the industry. Based on certain parameters and criteria, top Wholesalers, Retailers and Digjam Retail Showrooms were selected for the DIACHS Club.

Objective is to work together for mutual benefit and increase our business. To reward the good and consistent performers and to enter into a committed, long-term relationship with the Dealers. Membership valid for 1 year. The members have the following benefits:

Special incentive on turnover on achievement of a minimum turnover target (based on certain parameters). Special Qualities / Design Selection: Special qualities to be developed for Achievers Unlimited members. Participation and involvement of club members for range development.

Special samples of selected / fast moving qualities to be provided to club members. Achievers Unlimited Members Meet - To participate in DIACHS Meet organized once in a year. In such functions, the top performing members to be awarded and honored by top management.

Special Service: To give priority to them in order procurement and execution. Suit lengths to be dispatched to club members through courier on paid basis.

Special Certificate recognizing members as part of the Digjam Achievers Unlimited family.

The formation of this unique club was made know to the achievers at Dealers Meet organized at The Intercontinental, Goa in September, 2004.

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AWARDS & RECOGNITIONS

Table 1 Awards & Certification 1) Confidence in Textiles 2) ISO 9001:2000 3) Lycra Assured 4) Export House Certificate Year 2007 2007 2005 2004 ( Source: www.digjamsuiting.com)

Credentials Awards:
Highlights - Why Digjam is Ahead : 1. Using the best technology and machines available, Digjam has achieved the ISO 9001 international quality Certification. 2. Impressive capability: The present production capacity of over 20,000 meters of woolens per day is one of the highest in the industry. 3. Exporting nearly 35% if its total production. Digjam textiles are now in use in the U.S., Canada, U. K., Europe, Middle East Far East, Japan & Australia. 4. For four consecutive years, DIGJAM Limited has received the highest Exporter Award, in the woolen worsted category, from the export Promotion Council, a Govt. of India Undertaking. 5. Digjam is a Unit of the trusted Birla Group of Industries with a world-wide presence and strong reputation. 6. The first and only worsted mill in India to be awarded the status of "ACCREDITED MILL" from the internationally renowned DuPont.

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7. Woolmark & Wool blend mark license from International Wool Secretariat.

Digjam has been awarded the status of "ACCREDITED MILL" from the internationally renowned DuPont and is now a part of the elite LYCRA ASSURED Network, which is the world's leading supply chain for innovative, quality stretch fabrics. In this difficult business environment, alliances are becoming more important than ever and the ability to differentiate one's company is even more crucial. These two business needs are the drivers behind our decision to be part of the exclusive LYCRA ASSURED Network. The goal is to create value in the LYCRA ASSURED Network as a whole, thus making it the automatic first stop for the world's leading buyers looking for premium stretch solutions and the latest fiber and fabric innovations and new concepts. The expanded support and services planned by DuPont as part of the value delivered by membership in the Network are mentioned below: Early access to new DuPont technologies and exciting innovations not only for Lycra, but also for other important products like Teflon, Tactel, Coolmax, Cordura, Supplex, Thermolite, and technical support.

New revenue growth opportunities. Significant cost and competitive advantages. Constant promotion of LYCRA ASSURED Network benefits and the products of its partners to key buyers.

Keeps us at the forefront of stretch innovations. New global sourcing options - from fiber through garment. ATS fabric library. Exclusive or priority access to market research. Participation in exclusive retail and consumer promotions.

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FLOW CHART OF DIGJAM LIMITED

Prod. Planning & control department

Sales & marketing department

production department

Export department Human resource department

Finance department

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INTRODUCTION
Since production is the process of converting inputs into finished goods and services, it must be managed. It deals with proper use of manpower and machinery for transforming raw material into finished product. Production management deals with decision making related to the production process, so as to the resulting goods and services produced according to the specification, in the amounts and by the scheduled demanded and at minimum cost. Production is the process to create or manufacture the goods and services. It is the main process by which an organization sale their product after the production of goods and services. Production is a function of planning, organizing and controlling through which a unit convert the raw materials into finished goods. It includes the following:

Raw materials Procurement and storage of raw materials Manufactured products

DIGJAM Ltd. has a drastic manufacturing unit in Jamnagar with a working environment. It is mainly producing the fabric clothes through various process of production with starts from grey combing and ends with finished product that is called fabric.

Plant location
Section of plant is very sturdy job for any production unit because ultimately every organization wants to reduce their cost of production and also wants to get every facility near to the place as well as a good layout where it will produce its products. DIGJAM Ltd. Is located as a coastal region of Jamnagar at Gujarat because this land was given by H.H.Jamsaheb and which is helpful to import raw material like wool and export the finished product and also helpful for local transportation because of the remote town. Near to the plant all the facility are available like electricity, school, bank, stores, hospital, market, transportation, economical atmosphere, labors, machineries and securities. The total weaving capacity of the plant is 7 million meters p.a. The plant spread over 47 acres, employees 515 executives and a dedicated force of 1600 workers.

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Raw materials and products

Raw material is the basic need for a manufacturing unit through which the production process and operation cycle run. In DIGJAM Ltd. The raw materials are two types : MERINO wool (natural fiber) Polyester

1. MERINO wool MERINO wool is purchased mainly from Australia, South Africa Wool is natural fiber which is used to make the fabrics in DIGJAM. and certified for its quality by IWTO (international wool testing consignment from Australia must have the Australian wool testing recognized). 2. Polyester:Polyester is manmade fiber comes in DIGJAM from reliance and IOCL pondichery. Some variety of polyester is imported from Germany. Types of polyester used in DIGJAM are a) b) c) d) Semi dull Sparkling white Normal white Black and New Zealand. This wool is tested organization). The certificate (AWTC

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PRODUCTION PROCESS
DIGJAM Ltd. Completely vertically integrated plant located in Jamnagar has ultra modern production facilities to convert wool top to finished fabrics through different process of grey combing, dyeing, spinning, weaving, folding and finishing using state of the art machinery imported from France, Germany, Italy, Switzerland, Belgium and south Korea. The company manufactures more than 1000 quantities in over 3000 design shades combination each year in light wool and woolen fabrics for the DIGJAM brand alone and also free with practically no pollution.

PRODUCTION PPOCESS Grey combing (Top ready)

Dyeing

Spinning (Reduce thickness of roving)

Weaving

Finishing (chemical and mechanical)

Product prepare

Folding (inspection)

Length cutting and scathing

Stamping

Ready for export and domestic

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GREY COMBING DEPARTMENT

Greasy wool has import from South Africa and Australia. Order has been received in one and half month. Wool has reached at Bombay port and then by truck it reached at DIGJAM. 20tone wool is in one ship. The raw material (wool) received as per specification in different micron like 17.5 micron,18.5 micron,19.5 micron and 22.5 micron. Micron has been measured in terms of length.17.5 is standard micron as length wise.

Process of woolen fabric Raw-Material (Scouring)

process of polyester Tow cutting

Stretching Scoured wool (Carding) Fiber separation Card Sliver (Gilling)

Releasing

Gill Sliver (Combing)

Cutting

Gilling (3times) Top Top

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Objectives of grey combing: To clean the greasy wool Increase the mean length of the fiber Make in to the TOP form This is the very first and initial division as a part of the whole process. In the grey combing the raw material is greasy wool and polyester. So grey combing convert the wool and polyester inform of top which made by sliver. So here wool is import from countries like Australia, south Africa and New eland and polyester supplied from RIL, IOCL and also import from Germany. So grey combing has two ways to make the sliver: First from wool Second from polyester First from wool To remove all the undesired things and make the wool pure and ready for dye, there are four processes to make top form:1) 2) 3) 4) scouring Carding Gilling Combing

1) Scouring This is the process by which dirt, grease, perspiration, salt and vegetable matters are removed from the wool by washing it in non-ionic detergent (namely IGSURF and ALPHOX) and soda ash. This whole process contains five bowls, from which three bowls are used for washing the wool with detergent (at 62C,60C,60C temperature respectively) and rest two is used for washing wool with clean hot water (at 55C temperature)

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The process of scouring contains four steps; Reopening (wool opened manually is reopened)

Washing (wool is washing with detergent & warm water

Squeezing (Pressure is given to the washed wool)

Drying (wool goes for dry in dried chamber at 90C to 100C 2) Carding This is the process in which BURR and SHODDY are removed and cleaned it properly. The wool have to pass over thirty five roller in carding process. Main object of carding is to remove vegetable matter, opened up bunches and fleeces for separation of fibers, conversion of web to silver form.

3) Gilling Gilling is the process done before combing. In this, there is a comb like structure to blend different quality of card sliver together and make fiber parallel to one another. The multiple fibers are mixed to reduce the variation in quality i.e. average length and fiber fineness in lot. Main function of Gilling is to make uniform sliver by drafting,

Three consecutive Gilling is given in the process to reduce the variation in quality the fibers; Gilling-1 (ten carded slivers are fed to the machine and form one sliver) Gilling-2 (5 slivers are fed) Gilling-3

4) Combing Combing process is done to remove remaining vegetable matters, naps and short fibers which can create problems in spinning to generate drafting weave. The final product of combing is TOP and by product called NOIL.

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After Gilling the slivers are taken for post Gilling /top forming machine. Here the top gets desire wt. and be prepared for further process.

Second from polyester Polyester tow is purchased from Reliance and Germany. Bell wt.appr.300 kgs. Length cutting as per requirement. For combing the polyester and make it in TOP form there are some processes are as follow:1) TOW to TOP converter A TT machine is used to convert the tow in a single step machine. The tow is continuous so it has to be cut according to the length of wool fibers. The polyester is slant-cut with a rotating blade mounted on a drum. 2) Gilling This process is performed to parallelize the fibers. After this it is converted in to top and send to the dyeing and spinning department.

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Dyeing department Wool tops and polyester tops are dyed separately. There are 10 dyeing machines. Each machine having 3 cells and each cell having 3 tops and weight of each top is 7 kg. 30% compressing for press the material. 41 C is given to machine for complete dye. Material dyeing is done in three forms: Top dyeing Yarn dying Fabric dying

Some important point for dyeing

Wool is dyed at 100 C Polyester is dyed at 130 C Yarn is dyed at 120 C Light and medium shades are dyed for 30 minutes Dark shades are dyed for 45 minutes 100% wool can be dyed in the form of top or piece dyeing 100% polyester can be dyed either in top or piece. Polyester wool blend can be dyed in piece form only.

After dyeing the top, yarn and fabric they test the matching shade or color according to the customer order if any color mismatched with the real one they again dyeing the raw materials and after all these processes there is one another machine is called defelting machine. This machine is basically Gilling the top because the dyeing tops are slivered after the dyeing.

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RECOMBING DEPARTMENT

During the dyeing process, certain degree of disturbance takes place, so removal of that disturbance is required. For that re-combing process is required. Objective of re combing 1. to remove short fiber 2. to remove dirt and naps 3. to strengthen the fiber and make it parallel 4. to enhance blending Process of re-combing Hydro extractor

Back wash (dark shades)

Radio frequency (light shades)

Defelting

Gilling 4 times

Comber

Gilling 2 times

Auto leveler

Top ready for spinning

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SPINNING DEPARTMENT Raw for spinning is top which is final product of re-combing. Spinning applies draft to roving, then apply twist to bind the fiber together to make yarn. Process of spinning Gilling 4 times

Roving

Rubbing

Ring frame

Single yarn steaming

Double yarn steaming

Single yarn winding

Double yarn winding

Assembly winding

Twisting on TFO

Visual checking

Deliver to store

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1) Gilling Objective of Gilling 1. To make the fiber parallel by drafting, 2. To make the sliver even by evenization doubling

There are two sets of gill boxes 1) GN-5 2) GN-6 1set = 4gillboxes Namely, a, unicoiler with bollfiding b, uni coiler with auto leveler c, bi coiler d, tri coiler

2) Roving Objective of roving 1. To reduce the wrapping 2. To make suitable package Roving process include four machines, three machines for flyer frame and one for rubbing. Rubbing is end product for spinning preparatory.

3) Ring frame There are 27 spinning machines. Spinning include ring frame. Operation of ring frame is drafting and twisting. Ring frame include, a) spindle capacity of ring frame 400 b) total spindle capacity of shed 14800 c) speed of the machine 7000 9000 r.p.m 4) Single yarn steaming Objective of single yarn steaming 1. To remove snarling effect from yarn 2. To set yarn twist

5) single yarn winding

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Objective of single yarn winding 1. To remove fault from yarn 2. To kept appropriate size of packets This process is done by Autoconer machine. There are 5 Autoconer machines. 6) Double yarn steaming Steaming is done to fix the yarn from doubling. It makes strong yarn. Here, 2 machines for double yarn steaming.

7) Double yarn winding (rewinding) This is final process. There are two re-winding machines.

8) Assembly winding Objective of assembly winding 3. To combine two single yarn to make one yarn

9) Twisting on TFO Objective of TFO Is to twist two yarn make one in such a way it looked like a single yarn. Process has two steps 1. S twisting with Z 2. Z twisting with S There are 20 TFO machines

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Weaving department The function of weaving is to convert yarn into fabric. Process of weaving

Warping

Drawing

Winding

Grey inspection

Yarn comes from spinning department and stored in yarn store, According to requirement they provide yarn to weaving department. Sales department gives order to planning department and planning department gives order to weaving department. In 1st process warping, in this process yarn will arrange in rank, process will start on drum and drum will convert into beam. In 2nd process drawing, beam is converting into loom according to length and design. collect design from design & development department In terms of graph. Vertically and horizontally (warp & wept) design and arrange it accordingly.

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FOLDING AND FINISHING DEPARTMENT

Process of folding Final inspection

Stamping

Measuring $ cutting

Folding

Final inspection

Wrapping package

The fabric is checked and the defects are flagged according to their type. White flags are put on the faults which can be removed in the mending department. Red flags are put on the more severe faults which can not be removed and the fabric has to be cut from there. Then the measuring, cutting, stamping and folding of the fabric is done. Fabric is ready for sale.

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Design & development department Design is innovative and creative. Designer must expert to convert creativity into visual form. Designer makes visual communication, and it helps to satisfy the psychological and aesthetic needs of end user. Sources of design Direct feedback of customer Market survey International magazines which contains fabric cuttings. Designer intuition and past experience.

Design department makes sample through handloom and show that sample to sales department and finally send it to production department for the further processing. For selection of domestic design two conferences has been arranged. For export products have been prepared before one year.

Monitoring of design trends/seasonal needs and constant development work enable DIGJAM to respond rapidly to market demand and buyer needs. Higher standards of inspection at all stages, using the latest test equipment, ensures the near perfect quality and integrity of DIGJAM woolen textile multi terminal computers reinforce production control applicants.

FABRIC for that GREAT SUIT

QUOLITY CONTROL

DIGJAM MILL having international lab for quality control. It has different machinery like:1. Strength of thread is testing in one machine. 2. Testing the fiber length in average. 3. Microscope machine for testing diameter. 4. Air flow fiber for testing of stitching garment. 5. Fast instrument machine. 6. Drip meter. 7. Rubbing fast Check. 8. Pilling check. 9. checking(cross checking)

DIGJAM has been obtained its ISO 9001 certificate so it is highly conscious about quality apart from various quality checks after each and every process, the sample items are scientifically rechecked several at the centralized quality control department. To check the raw materials several test are required i.e. yield % test, grease % test, dust and mud % test for the checking of vegetable items. With the use of microscope, alimeter test is done to verify the length parameter, average length, oil % test and diameter of wool top. The same process is used to check the quality of re combed top. In this laboratory fastness and moisture is also checked. There is an in house checking in yarn stage. Moreover, the strength of yarn and pilling check is also done. There is a steam testing machine to test the shrinkage.

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(QUOLITY IS DIGJAMS LIFE)

QUALITY POLICY

We, as a company are committed to: Produce wide spectrum of quality fabrics/ products at competitive price to satisfy the need and expectation of our valued customer. Our goal is to enhance customer satisfaction through continual improvement. This shall be achieved by:1. Implementing quality management system as per ISI/ISO 9001:2008 in the company in letter and spirit. 2. Setting and reviewing objectives of various functions in the company. 3. Providing necessary training where applicable. 4. Reducing waste and defective % age during various stages of production.