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QUALITY CONTROL SYSTEMS STUDY REPORT OF

SYNTECH FIBRESFOR THE SUBJECT

TOTAL QUALITY MANAGEMENT

GROUP MEMBERS

S R .# N A M E1 2 3 4 SAAD KHAN KAKERZAI ZAIN HASSAN NOUREEN FATIMA FAIZ AKHTAR

STUDENT IDSP09-BB-0083 SP09-BB-0111 SP09-BB-0072 SP09-BB-0023

SUBMITTED TO SIR SAEED MUJAHID ASSISTANT PROFESSOR MARKETING DEPARTMENT MOHAMMAD ALI JINNAH UNIVERSITY (MAJU) KARACHI

SYNTECH FIBRES

SYNTECH FIBRES

DEDICATION

Our beloved teachers and parents, whose blessings and concentration brings us to this stage and who trample their inclination and longing for up holding our studies.

SYNTECH FIBRES

LETTER OF ACKNOWLEDMENT

This report is a study and analysis of Quality Control System in an organization named as Syntech Fibres (Pvt) limited which has been prepared as a part of the course requirement for Total Quality Management. The material compiled and presented in this report is a result of hard work. This report has proved to be a great experience. For this, We would like to thank our Almighty ALLAH who made everything easier to us and then our Instructor Mr. Saeed Mujahid who provided us the path of knowledge and guidance. Sincerely, Group Members: Saad Khan Zain Hassan Noureen Fatima Faiz Akhtar

SYNTECH FIBRES

TABLE OF CONTENT

S.No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Description Organization Overview Organizational Hierarchy Main Business Function of Organization Quality Policy Duralene Yarn and Fibre About Polypropylene Production Process Quality Assurance, Kaizen Aqua Clear Filters Working of Aqua Clear Filter Types Of Cartradiges Comparison with Conventional Media Features of Aqua Clear Cartradige Standardes Production Process Other Business Function

Page No 5 6 7 8 9 10-11 12-16 17 18-19 20 21-22 23 24 25 26-27 28-31

SYNTECH FIBRES

S Y N T E C H F I B R E S (P R I V A T E ) L I M I T E D

ORGANIZATION OVERVIEW:Established in 1987, Syntech Fibres serves customer with Duralene polypropylene fibres and yarns. Polypropylene is one of the most versatile available today. It is used in highly diverse products such as apparel, home upholstery, automotive, contact furniture, carpets, and industrial applications. Syntech Fibres aims to become the preferred supplier for propylene fibres and yarns. In order to achieve this ambition, Syntech Fibres works continuously on further product improvement and offers active support to customers towards the development of new products and areas of application. Customers can account on Syntech Fibres continued commitment to research and development. Over the years, Syntech Fibres has built up to unique know how and expertise in the production and processing of propylene fibres and yarns. Syntech Fibres is striving continually to improve and expand the company existing product and application, while at the same time introducing new products to meet evolving market requirement and customer needs. As the market leader in polypropylene fibres and yarns, Syntech Fibres ongoing efforts are aimed as improvement of existing products and development of new products in order to meet changing customer needs.

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MOHAMMAD ALI JINNAH UNIVERSITY

S Y N T E C H F I B R E S (P R I V A T E ) L I M I T E D

ORGANIZATIONAL HIERARCHY

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MOHAMMAD ALI JINNAH UNIVERSITY

S Y N T E C H F I B R E S (P R I V A T E ) L I M I T E D

MAIN BUSINESS FUNCTION OF THE ORGANIZATION:Syntech Fibres is mainly producing Polypropylene fibres and Yarns. They are also producing many downstream products such as upscale office upholstery fabrics, narrow fabrics, area rugs, filter yarns and filter cartridges in a variety of colors, deniers, cross sections and finishes to suit a wide range of applications. Yarns include continuous filament flat yarns, BCF yarns, air textured yarns, interlaced yarns, twisted and plied yarns, fibrillated yarns, industrial sewing yarns and cords, heat set knit-de-knit yarns, spun yarns, special effect fancy air textured yarns, filter yarn, roving and monofilaments.

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MOHAMMAD ALI JINNAH UNIVERSITY

S Y N T E C H F I B R E S (P R I V A T E ) L I M I T E D

QUALITY POLICY

To provide quality solutions to meet customer requirements. To continually improve our quality systems. To improve the efficiency and effectiveness of our people and processes. To be the market leaders in polypropylene yarns and filter cartridges. To maintain a safe working environment. To comply with all applicable laws.

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MOHAMMAD ALI JINNAH UNIVERSITY

S Y N T E C H F I B R E S (P R I V A T E ) L I M I T E D

CORE PRODUCTDURALENE POLYPROPYLENE YARNS AND FIBRES:Syntech fibres are producing best quality yarns and fibres from polypropylene and supplying to most of the industrial units in Pakistan and as well as exporting it to many countries. Products using polypropylene fibres and yarns last longer, are lighter, have greater resistance, and are more advanced, and more efficient than products using conventional materials. Syntech Fibres are producing silky soft to coarse and tough yarns, 300-10,000 denier range are available, in 2 to 30 denier per filament and 13 to 100 mm staple lengths, in bright, semi-bright, semi-dull and dull finishes. Duralene fibres and yarns can be tailor-made to suit customer applications.

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MOHAMMAD ALI JINNAH UNIVERSITY

S Y N T E C H F I B R E S (P R I V A T E ) L I M I T E D

ABOUT POLYPROPYLENE:Polypropylene has the lowest specific gravity of all fibres (0.91), making it the lightest of all textile fibres. Low specific gravity also means that it takes 20% to 41% less polypropylene fibre to produce fill and densities equivalent to fabrics made from nylon, acrylic, polyester, rayon/acetate, cotton or wool. Duralene polypropylene yarn is strong, colorfast, and inherently resistant to stains and soils, abrasion, mildew, perspiration, and inclement weather. These qualities make it an ideal fibre for home upholstery, automotive, contract furniture, carpets, apparel and industrial applications. Polypropylene applications for apparel include denim jeans, active wear, undergarments and socks, and industrial products such as ropes, webbings, filter fabrics, and geotextiles. Polypropylene has the highest growth rate among man-made fibres and more than twice the growth rate of any other fibre. With a greater market share than nylon, and second only to polyester, it is a leading synthetic fibre used for textiles.

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MOHAMMAD ALI JINNAH UNIVERSITY

S Y N T E C H F I B R E S (P R I V A T E ) L I M I T E D

INHERENT CHARACTERISTICS: Good

bulk and cover, very lightweight High strength (wet or dry) Resistant to deterioration from mildew, bacteria, perspiration, rot and moisture Outstanding resistance to chemicals Abrasion resistant (durable) Low moisture absorption Stain and soil resistant, pill resistant, odor resistant Good wash ability, quick drying, unique wicking Sunlight resistant (with UV additive), colorfast Resilient, very comfortable Low

static, low thermal conductivity Non-allergenic

TYPES DURALENE POLYPROPYLENE YARNS AND FIBRES:Following are the types of polypropylene yarns and fibres syntech fibres are producing: Continuous

Filament Flat Yarn Interlaced/Intermingled Yarn Twisted and Plied BCF (Bulked Continuous Filament) Air-Textured Special Effect Fancy Air-Textured Yarn Carpet yarns: heat set, single ply, cabled, frieze, knit-de-knit Industrial Sewing Yarns Tape Yarn Fibrillated Tape High tenacity fibres and yarns Monofilaments Staple fibre Yarn for grass carpets Fibres for reinforcement of concrete

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MOHAMMAD ALI JINNAH UNIVERSITY

S Y N T E C H F I B R E S (P R I V A T E ) L I M I T E D

PROCUREMENT PROCESS

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MOHAMMAD ALI JINNAH UNIVERSITY

S Y N T E C H F I B R E S (P R I V A T E ) L I M I T E D

PURCHASE ORDER:Order received from customer according to his specification which he finalized after checking the color card to see our range of standard colors. From silky soft to coarse and tough yarns, 30010,000 denier range are available, in 2 to 30 denier per filament and 13 to 100 mm staple lengths, in bright, semi-bright, semi-dull and dull finishes.

IMPORTS:The raw material is imported from the gulf countries such as Oman & Saudia Arabia. It takes about 2 to 3 months to import raw material. Syntech fibres keep their records/inventory up to date so that they dont have to face the problem of inventory ending. A container full of polypropylene is imported from gulf countries on monthly basis.

WAREHOUSE:After receiving the order from customer we check that whether we have enough inventory (polypropylene) available in warehouse. If yes then we sent it to the factory for further processing. If, we dont have the required inventory available then raw material is imported from gulf countries such as Oman & Saudia Arabia. When raw material (polypropylene) is received through shipments then it is first sent to inspection laboratories, they take a random sample and test it whether it meets our quality criteria or not. After the clearance report from laboratories the raw material (polypropylene) is sent to the factory for production.

PRODUCTION:After the receiving of raw material (polypropylene) in the factory. It starts with the following process: MELTING PROCESS: The polypropylene is transferred into a container through which it is sucked into the heater and melted at very high temperature so that the polypropylene is transformed into yarn and fibre. INSPECTION: Workers who are operating the machine check the product quality in order to ensure that the product is according to the specification. They take random s