Report On Textile Industry Of Surat.

A REPORT ON

NIKUNJ SILK MILLS TO STUDY APPLICATION OF PRODUCTION MANAGEMENT

DONE AT

NIKUNJ SILK MILLS

SUBMITTED TO:

SUBMITTED BY:

PATEL GHANSHYAM (62) PATEL GIRISH (64) RAJPUT GITESH (81) SHAH AMAN (90) TRIVEDI SAGAR (111)

Miss JAGRUTI MADAM (Lecturer)

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

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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. 2. 3. 4.

Confirmation Letter

5

Introduction Plant Layout Manufacturing Process - Graphical Presentation - Winding Machine - T.F.O. Machine - Warping Machine - Passing - Bobbin Machine - Power Looms - Mending & Folding

5.

Material Handling System

6 7 11 12 15 16 18 19 20 21 22 24

6.

(Equipment & classification) 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,

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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.

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Third Floor - warping, office & ready stock.

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Raw Material (Yarn)

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Winding Machine

T.F.O. Machine

Steam Machine

Bobbin Machine

Palti Machine

Warping Machine Passing

Power looms Machine Finish Goods (Grey Cloth)

Brief Description of Process

12

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 14

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 20

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. 25

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 yarnRussian. 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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