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 MADAMPATEL 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

(Equipment & classification)

24

6. Inventory & Quality Control 28

4

Date:

Nikunj Silk Mills39, Uma Industrial Soc.,Bhatar Road, Surat.Mob: 9898616752

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.

5

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,

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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PLANTLAYOU

T7

8

The first floor - 48 looms and two bobbin machines.

9

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

10

Third Floor - warping, office & ready stock.

11

12

Raw Material (Yarn)

Brief Description of Process

13

Winding Machine

T.F.O. Machine

Warping Machine

Bobbin Machine

Power looms Machine

Palti Machine

Finish Goods (Grey Cloth)

Steam Machine

Passing

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)

14

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

16

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.

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WARPING MACHINE

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

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PASSING

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.

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POWER LOOMS

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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23

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.

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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Material25

Handling

System(Equipment & Classification)

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.

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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.

27

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.

This is a Bobbin Machine which

makes bobbins of Yarn.

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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.

And this kind of Gray clothe is prepared

which can be sold to the market.

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&

30

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.

The scopes which are ready should

be put on the proper place.

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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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