vardhaman report
DESCRIPTION
internship reportTRANSCRIPT
OBJECTIVE OF INTERNSHIP
To understand the concept of spun yarn production, dyeing, printing and finishing of
yarns, testing and their quality aspects both technical as well as for commercial
purpose.
The machinery features, machine and material process parameters have been
described in detail in the areas as mentioned below:
Assignment – 1:
Observations to be made and information to be documented on the Yarn
manufacturing
and winding section:
A. Raw material storage and inspection section.
B. Blow room section.
C. Carding section.
D. Drawing section.
E. Combing section.
F. Roving section.
G. Spinning section.
Assignment – 2:
Observations to be made and information to be documented on the Dyeing section
Assignment – 3:
Observations to be made and information to be documented on the Testing and
Quality control sections
1
GROUP PROFILE
Vardhman Group is a leading textile conglomerate in India having a turnover of
$700 mn. Spanning over 24 manufacturing facilities in five states across India, the
Group business portfolio includes Yarn, Greige and Processed Fabric, Sewing
Thread, Acrylic Fibre and Alloy Steel.
Vardhman Group manufacturing facilities include over 8,00,000 spindles, 65 tons per
day yarn and fibre dyeing, 900 shuttleless looms, 90 mn meters per annum
processed fabric, 33 tons per day sewing thread, 18000 metric tons per annum
acrylic fibre and 100,000 tons per annum special and alloy steel.
Vardhman has evolved through history from a small beginning in 1965 into a modern
textile major under the dynamic leadership of its chairman, S.P.Oswal. His vision and
insight has given Vardhman an enviable position in the textile industry. Under his
leadership, Vardhman is efficiently using resources to innovate, diversify, integrate
and build its diverse operations into a dynamic modern enterprise.
An Insight into the Vardhman Logo:
The “Flame” signifies the growth of each and every individual
associated with it whether he or she is a worker, an employee,
share holder or a customer.
The “Stick” symbolises cotton, which is basic raw material of the core product
of Vardhman Group.
The “V” stands for Vardhman Group.
2
MISSION:
Vardhman aims to be world class textile organization producing diverse
range of products for the global textile market.Vardhman seeks to achieve
customer delight through excellence in manufacturing and customer service
based on creative combination of state-of-the-art technology and human
resources. Vardhman is committed to be responsible corporate citizen.
PHILOSOPHY:
Faith in bright future of Indian textiles and hence continued expansion in
areas “which we know best”.
Total customer focus in all operational areas.
Product to be of best available quality for premium market segments through
TQM and Zero Defect Implementation in all functional areas.
Global orientation targeting atleast 20% production for exports.
Integrated diversification/product range expansion.
World-class manufacturing facilities with most modern R&D and process
technology.
Faith in individual potential and respect for human values.
Encouraging innovation for constant improvements to achieve excellence in
all functional areas.
Accepting change as a way of life.
Appreciating our role as a responsible corporate citizen.
3
HISTORY
The industrial city of Ludhiana, located in the fertile Malwa region of Central Punjab
is otherwise known as the "Manchester of India". Within the precincts of this city is
located the Corporate headquarters of the Vardhman Group, a household name in
Northern India. The Vardhman Group, born in 1965, under the entrepreneurship of
Late Lala Rattan Chand Oswal has today blossomed into one of the largest Textile
Business houses in India.
At its inception, Vardhman had an installed capacity of 14,000 spindles, today; its
capacity has increased multifold to over 8 lacs spindles. In 1982 the Group entered
the sewing thread market in the country which was a forward integration of the
business. Today Vardhman Threads is the second largest producer of sewing thread
in India. In 1990, it undertook yet another diversification - this time into the weaving
business. The grey fabric weaving unit at Baddi (HP), commissioned in 1990 with a
capacity of 20,000 meters per day, has already made its mark as a quality producer
of Grey poplin, sheeting, shirting in the domestic as well as foreign market. This was
followed by entry into fabric processing by setting up Auro Textiles at Baddi and
Vardhman Fabric at Budhni, Madhya Pradesh. Today the group has 900 shuttleless
looms and has processing capacity of 90mn meters fabrics/annum.
In the year 1999 the Group has added yet another feather to its cap with the setting
up of Vardhman Acrylics Ltd., Bharuch (Gujarat) which is a joint venture in Acrylic
Fibre production undertaken with Marubeni and Exlan of Japan. The company also
has a strong presence in the markets of Japan, Hong Kong, Korea, UK and EU in
addition to the domestic market. Adherence to systems and a true dedication to
quality has resulted in obtaining the coveted ISO 9002/ ISO 14002 quality award
which is the first in Textile industry in India and yet another laurel to its credit.
4
PORTFOLIO:
The group portfolio includes Yarn, Fabrics, Sewing Thread, Fibre and Alloy Steel.
Business Wise Turnover for the financial Year
2010-11
Actual 2010-11Group Total
(Rs crore)USD Million
Yarn 2280 500
Fabric 1093 240
Sewing Thread 440 97
Steel 435 95
Power plant 9 2
Fibre 235 52
Total 4492 986
5
Yarns
Yarn Manufacturing is the major activity of the group accounting for 51 percent of the
group turnover. Vardhman is virtually a supermarket of yarns, producing the widest
range of cotton, synthetics and blended, Grey and Dyed yarns and Hand Knitting
Yarns, in which Vardhman is the market leader in India. The group has twenty one
production plants with a total capacity of over 8.8 lacs spindles, spread all over the
country. In many of the yarn market segments, Vardhman holds the largest market
share. Vardhman is also the largest exporters of yarn from India, exporting yarns
worth more than USD 282 million.
PERFORMANCE:
During the last 16 years, Vardhman Group has recorded 13 percent top line growth
rate, which is higher than the industry average growth rate. The Group turnover has
grown from Rs 723 crores in 1995 to Rs 4492 crores (about USD 986 million) in
2010-11. The exports has grown from negligible level in early nineties to Rs 1287
crores (USD 282 million) in 2010-11.
Financial Indicators Of Vardhman Group (Rs. In Crores)
Particulars Group Group Group Group Group
2010-11 2009-10 2008-09 2007-08 2006-07
Gross Sales 4492.16 3391.39 3186.32 2692.93 2454.00
Fob Value Of Exports 1286.79 751.89 688.67 495.73 482.93
Profit Before Tax 755.36 411.32 137.41 204.8 264.73
Cash Accrual (PBT + Dep.) 1020.03 667.96 380.79 376.74 398.32
Gross Block 4415.57 4176.40 3935.47 3460.86 2467.71
Net Block 2690.45 2598.58 2571.33 2219.22 1386.84
Capital Employed 5753.88 4747.86 4555.61 3917.86 3181.18
6
Gross
Sales
Fob Valu
e of E
xports
Profit B
efore
Tax
Cash Accr
ual (PBT +
Dep)
Gross
Block
Net Block
Capita
l Employe
d0
1000
2000
3000
4000
5000
6000
7000
2006-072007-082008-092009-102010-11
PRODUCTS:
Cotton Yarn
Organic Cotton Yarn
Organic Fair Trade Cotton Yarn
Ellitwist Yarn
Vortex Yarn
Slub Yarn
Acrylic Yarn
Synthetic blends
Synthetic Cotton blends
Special Blended Yarn
Core Spun Yarn
Melanges
Gassed Mercerised Yarn
Modal Yarn
Tencel Yarn
Hand Knitting Yarn
Speciality Yarn
CUSTOMER FOCUS:
7
At Vardhman, each customer is special and a constant source of inspiration.
Therefore, the Group has leveraged technology to develop a highly sensitive
response system for addressing customer needs. A high-tech in-house
sampling unit and a design studio enable Vardhman to provide customers with the
most innovative products. Vardhman has also implemented Enterprise Resource
Planning (ERP) System to provide facilities like online tracking of orders.
HUMAN RESOURCES:
The human resource development at Vardhman is aimed at enabling people
discover their true potential. The company endeavours to provide opportunities to
experiment with a strong culture built around talent, team work, competitive spirit,
continuous learning, trust and transparency. The well-designed system of
knowledge dissemination across various levels ensures access to intellectual
capital. The knowledge bank facilitates individual growth and excellence. Vardhman
believes that winning leaders are teachers and winning organisations always
encourage and reward teaching. The business processes, organisational structure
and day to day operating mechanism promote teaching for developing a stream of
young leaders.
The calibre and professionalism of its people has helped Vardhman achieve and
maintain its leadership in the competitive environment of today. The Group has
initiated a number of human resource development processes to facilitate
consistent improvement in performance, productivity and effectiveness.
Vardhman believes in continuous learning and adapting to change as a way of life.
Preparing for transformation, the Group has designed elaborate training and
development programmes that encompass the technical, managerial, behavioural
and spiritual growth of its employees. Vardhman Training and Development
Centre at Ludhiana, caters to the distinct needs of its employees, where training
programmes are conducted throughout the year by in-house and external faculty.
Manav Vikas Kendras and Quality Circles are also similar initiatives where trained
faculty impart regular training, especially to workmen. Apart from this, managers
participate in training at some of the best institutes like the Harvard Business
8
School (USA), Institute of Management Development (Switzerland), ISB and IIMs in
India. Vardhman sincerely believes that when technology converges, people will
make all the difference.
THE SOCIAL DIMENSION:
As a commitment to the society and the workforce, Vardhman has provided
schools for the children, functional residential complexes for employees and
working women hostels for single women workers. Numerous recreational activities,
sports programmes and cultural events during festivities are regularly organised.
Besides these, the Company runs medical camps to meet the health requirements of
the people.
Sri Aurobindo College of Commerce and Management in Ludhiana and the
Aurobindo Public School at Baddi (Himachal Pradesh) are stellar examples of how
Vardhman is involved in providing specialised education and improving
competence levels in the society at large. Responding to the call for inclusive
growth, Vardhman Group has started a Capability Enhancement Training
Programme for socially under-privileged students on regular basis. The training
aims at enhancing the employability of under-privileged students belonging to
scheduled castes, scheduled tribes and other backward classes.
The Vardhman Group made earnest efforts to increase the income of cotton
growing farmers by imparting training to them on various aspects of cotton
cultivation through “Village Adoption Programme”. As a result of these efforts, the
cotton productivity of the adopted villages increased manifold and has crossed the
national cotton productivity average.
9
ENVIRONMENTAL CONSCIOUSNESS:
Decreasing green belts and ever increasing pollution has become the bane of
modernization. Vardhman has always made a conscious effort not only to preserve
the environment around us but also to contribute its mite towards building a better
world. A corollary of this consciousness is visible in the best pollution control
devices and practices. Vardhman has also increased green cover across all
manufacturing units. Going further, Vardhman group actively pioneered the setting -
up of Nimbua Greenfield Punjab Limited, a company dedicated to solid waste
treatment, storage and disposal in the State of Punjab, India.
10
VARDHMAN SPINNING & GENERAL MILLS
LTD. (LUDHIANA) – VSGML
This unit was installed in august 1965 with 12000 spindles and as on date the
number of spindles has increased to 59728 indulged in the manufacturing processes
like spinning, worst & knitting yarn. Here acrylic woolen, dyed yarn and worsted yarn
is manufactured. The yarn of this unit is widely accepted in the market and is
exported to various countries in the world.
Manufacturing activityCotton Spinning, Worsted
Spinning, Dyeing
Production activity 24,496 spindles
Major customers
Domestic: Orient Crafts Ltd.,
Gurgaon; Soma Textiles;
Raymonds; Arvind; V and S;
Matrix; Richa Global Ltd. etc.
Export: Hansole, Korea; Ecolex,
Bangladesh; Chauri, Japan etc.
Yarn Count Spun 20s, 28s, 30s, 34s, 37s
Quantity of Cotton Consumed/day 20 tonnes
Quantity of Manmade Fibres
Consumed/day7 tonnes
Average Ring Frame Utilisation/Day 97.10%
Address
Vardhman Spinning and General
Mills Ltd.,Chandigarh Road,Near
Samrala Chowk,
Ludhiana – 141010, Punjab.
11
VSGML AS A TEAM:
VSGML has various operations with in itself. Following are the departments, which
helps in achieving the set objectives of VSGML:
1) Production
2) Engineering
3) Maintenance
4) Research & Development
5) Training
6) Costing & MIS
7) Materials & Stores
8) Industrial Relations
9) Personnel & Administration
12
QUALITY MANAGEMENT TECHNIQUES
At Vardhaman Spinning and General Mills, Ludhiana, quality management
techniques are given a lot of credit and are followed religiously. One of the major
quality management techniques followed by them is Total Productive Maintenance
(TPM).
Total Productive Maintenance is a maintenance program which involves maintaining
plants and equipment. The goal of the TPM program is to markedly increase
production while, at the same time, increasing employee morale and job satisfaction.
TPM brings maintenance into focus as a necessary and vitally important part of the
business. Down time for maintenance is scheduled as a part of the manufacturing
day and, in some cases, as an integral part of the manufacturing process. The goal
is to hold emergency and unscheduled maintenance to a minimum.
TPM starts with 5S. Problems cannot be clearly seen when the work place is
unorganized. Cleaning and organizing the workplace helps the team to uncover
problems. Making problems visible is the first step of improvement.
Japanese TermEnglish Translation
Equivalent 'S' term
Seiri Organisation Sort
Seiton Tidiness Systematise
Seiso Cleaning Sweep
Seiketsu Standardisation Standardise
Shitsuke Discipline Self - Discipline
13
KAIZEN
"Kai" means change, and "Zen" means good ( for the better ). Basically kaizen is for
small improvements, but carried out on a continual basis and involve all people in the
organization. Kaizen is opposite to big spectacular innovations. Kaizen requires no
or little investment. By using a detailed and thorough procedure we eliminate losses
in a systematic method using various Kaizen tools. These activities are not limited to
production areas and can be implemented in administrative areas as well.
In the organization, workers are encouraged to come up with new techniques or
solutions for problems or methods which have a better efficiency to eliminate losses.
The method along with the result and the name of the employee who has suggested
the change are put up next to the machine or department where it is to be
implemented. This motivates the employees to use the various Kaizen tools more.
14
Total Productive Maintenance instructions and methods have been put up in the factory to increase awareness
ORGANIZATIONAL STRUCTURE
15
Chief Managing Director
MR. S.P. OSWAL
Executive DirectorMR. SACHIT JAIN
Vice-President (Commercial & Administration)
Chief Manager
Executive, Officers &
Staff
Managers (Accounts/HR/Costi
ng/Commercial)
Executive, Officers &
Staff
Vice President (Production)
MR.VINEET PANDEY
Asst. Vice President
(Engineering)MR. DHEERAJ
MEHTA
Chief Manager (Worsted)MR. J.S. REKHI
Executive, Officers & Staff
Production Supervisors
Workmen
Senior Manager (Spinning 1 & Spinning 2)
MR. VASANT BISEN
Executive, Officers & Staff
Production Supervisors
Workmen
Manager (Dye House)
MR. ATUL VERMA
Executive, Officers &
Staff
Production Supervisors
Workmen
ASSIGNMENT- 1
16
PROCESS FLOW OF COTTON SPINNING
17
Opening & Sorting
Mixing
Blowroom
Carding
Pre-Combing
Combing
Draw Frame
Speed Frame
Ring Frame
Winding
Conditioning
Packing
BLOWROOM
OPENING, SORTING AND MIXING
This process involves opening of fibre bales and opening tufts of cotton into smaller
tufts and removal of foreign materials. Mixing and sorting is done to:
Reduce the cost of raw materials
Have a uniform distribution of different types of cotton
Moisturise the cotton and allow them to open up
While mixing, it should be considered that fibres should have identical properties like
length, strength etc. Price, colour and grade of cotton should be of approximately
same quality. Optimum amount of different varieties should be mixed to keep the
quality up to the mark. Soft waste should be added as per requirement.
Mixing: The material from the compressed bales are torn into small flocks manually
and stored into the mixing room for 12 hours. Meanwhile, the fibres absorb the
moisture from the air and get conditioned. Oil and water are sometimes used in the
mixing room and they are sprayed on the mixed lot. The mixture helps to moisturise
the material and reduce the fly and fluff in the mixing room.
Sorting: It is the procedure in which the compressed bales are broken into small
tufts which is done manually. Contaminations are sorted out in this process.
18
Technical Specifications for Cotton
Cotton Varieties Usedi. J-34 (70%)
ii. S-6 (30%)
Bale Size 25” x 17” x 49”
Bale Weight 165-170kg
Cotton Varieties Parameters
Parameters J-34 S-6
Staple Length (mm) 28-29 29-30
Strength (gm/tex) 30-31 30-31
Elongation (%) 5.1-5.2 5.2-5.3
Micronnaire 4.8-5.0 3.8-4.2
Reflection Degree (Rd) 72-76 76-80
Brightness (B) 8-9 8-9
Technical Specifications for Polyester
Bale Size 39” x 25” x 49”
Bale Weight 400 kg
Length of Fibre 44mm
Count of Fibre 1.2 Dtex
Lustre Bright
Technical Specifications for Acrylic
Bale Size 40” x 24” x 46”
Bale Weight 300-350 kg
Length of Fibre 40mm
Count of Fibre 1.3 Dtex
Lustre Bright
19
Godowns Within The Mills:
SR.
NO.
GODOWN
NO.
LENGTH
(in ft)
WIDTH
(in ft.)
AREA
(in sq.
Ft.)
MATERIAL STORAGE
1 114 160 85 13600 Acrylic Fiber, Nylon Fiber,
Polyester Fiber
2 67A 100 60 6000 Acrylic Tow
3 105 100 60 6000 Acrylic Tow & Fiber
4 55 75.2 60 4512 All Types of Filament Yarns
5 33 80 90 7200 Raw Cotton
6 35 75 80 6000 Raw Cotton
7 105A 100 60 6000 Grey Yarn
8 66 60 42 2520 Grey Yarn
9 66A 43 50 2150 Grey Yarn
10 37 66 44 2904 Grey Yarn
11 63 66 47 3102 Grey Yarn
12 64 66 47 3102 Grey Yarn
13 36 152 45 6840 All types of waste
SR.
NO.
GODOWN NO. LENGTH
(in ft.)
WIDTH
(in ft.)
AREA (in
sq. Ft.)
MATERIAL STORED
1 S.T.-II Godowns
(A)
95 92 8740 Raw Cotton
2 S.T.-II Godowns
(B)
95 92 8740 Raw Cotton
3 S.T.-II Godowns
(C)
95 92 8740 Raw Cotton
4 S.T.-II Godowns
(D)
59 47.5 2805 Raw Cotton
20
In the blowroom, input is being fed in the form of cotton bales and the output appears
in the form of flocks. The main function of blow room is the opening, cleaning and
mixing of bale.
The main identifiable impurities are being removed by the machines at the farming
stage, the process is called ginning. Ginning process removes the main impurities
like seed coats, hair, stones, plastic, jute, cords etc. After ginning cotton bales are
formed in the compressed form. Each bale weighs approx 170 kg. Sometimes,
imported bales weigh even up to 300 kg.
The blow room of UNIT-I consists of 2 lines: Line-I and Line-II. Each line is formed by
the laydown of bales in the form of stack one over another, approximately 50 in
number.
Mixing can also be done at this stage by creating a laydown which consists of two or
more varieties, in the approximate ratios, according to the end-product requirement.
21
Blowroom: Laydown of cotton bales before mixing and sorting
Machines used:
22
UNIFLOCK
CONDENSER
MAXI FLOW
HEAVY PARTICLE
SEPARATER- ASTA
MPM
CVT-3
SECUROMATC-4 CARDDK CARD
Unifloc A-10
Manufacturer: RIETER
This machine is used pluck the flocks out of the laid down bales, basically with the
help of suction. It consists of a take-up unit which is connected by vacuum. It has 2
types of rollers: 1 beater roller and 2 stripper roller.
The 2 stripper rollers consist of metallic blades on its surface, which penetrate inside
the bales for better grip on both the sides.
In between are the main rollers i.e. the beater rollers, which again have got spikes on
its surface. Its main function is to open the compressed bales and pluck out the
fibers, so that they can be sucked by the pneumatic action.
Traversal speed of take - up unit = 10.5m/min
Capacity of the machine = 1000kg/hr
In addition, the workers also pick the noticeable trash by hand like: hair, jute, plastic,
paper, stones etc. they also open the bunch of fibres manually.
23Sorting and Mixing done by the Unifloc Machine.
TRANSPORTATION PIPES:
The flocks plucked in Uniflock through chute-feed system,(the pipes utilize
pneumatic action to pass on the plucked fibres) get more opened, while travelling
through the duct. In between there is also a metal detector which detects the
presence of any metal pieces inside the flocks and the damper diverts it into the
waste bag.
The ducts/pipes have been given colour coding:
Sr.
NoColour Code Function of Pipeline
Diameter
of Pipes
(mm)
Location
1 Green Material
Transportation
300 In all machines (Blowroom and
Card)
2 Blue Waste Transportation 220,300,55
0
MFC, CVT-3, Comber
3 Yellow Microdust
Transportation
300 LVSA, CVT-3, SP-F, Card
4 Red Fire Diversion 300 MFC, MPM,SP-F, Card
In case of spark inside the FBK pipes due to friction/metal particles, the entire
material inside the ducts is diverted outside the unit for preventing the fibre from
spreading.
CONDENSER:
Manufacturer : Trutzschler
Once the material has been passed through the metal detector, it goes to the
Condenser where the heavy particles are sucked and they fall down. Thus, in this
way the material is further cleaned.
24
MAXI FLOW:
Manufacturer : Trutzschler
The material is dropped in the machine by gravity through the Condenser and
advances with the beater action. The dust and contamination is separated and falls
down. The material is removed from the maxi flow with the help of suction from the
maxi machines.
SEPARATOR:
Manufacturer : Trutzschler
Heavy Particle Separator is a simple equipment working on aero-dynamics principle.
The machine removes contaminations in the mixing such as metal parts and other
heavy impurities which may otherwise cause damage to expensive blow room and
carding machinery.
25
Asta: Heavy particles are separated in this machine before they go to MPM-4 and MPM-6.
MPM:
Manufacturer : Trutzschler
The multi-mixer ensures a good blending at the beginning of the spinning process
which is essential for a uniform distribution and representation of all fibre
components into the yarn cross-section. This needs to be achieved during the
spinning processes as it cannot be achieved by the later processes alone. Proper
blending avoids variation in running conditions, yarn strength, uniformity and dye
take-up. The multi-mixer is usually available in 4, 6 or 8 chambers. In Vardhaman,
there were two lines one containing the 6 chamber MPM and the other containing an
8 chamber MPM.
CVT-3
Manufacturer: Trutzschler
This is another machine which is used for cleaning of the material. First of all, the
feed roller feeds the material inside the machine. Then it passes through three
spikes beater of increasing spike intensity, which carries out the opening. It has a
color contamination sorter (CCS).
Width of the machine :1600mm
Capacity: 600- 800 kg/hr
26
SECUROMAT:
Manufacturer : Trutzschler
Foreign fibre detection takes place at the end of the blowroom line and directly
before the cards, where the opening degree of the fibres has reached a maximum
value, the foreign parts, however, are still existing in a coherent form.
The separation of the foreign parts is effected by means of 32 compressed air
nozzles (10) distributed over the total working width of 1600 mm, which can be
individually controlled by pneumatic valves, in fact exactly at the point where a
foreign part is located on the surface of the needle roll.
27
CARDING
Manufacturer: Lakshmi Rieter
No. Machines: 10
Manufacturer: Trutzschler
The carding process essentially involves the opening of fibre aggregates by working
between two closely spaced surfaces covered with inclined wires. The main objects
of carding are:
To carry further process of fibres opening to a state of fibre individualization
To remove neps, tiny lumps of fibres
To deliver a continuous sliver for further processes.
To remove impurities from the material by individual fibre separation.
To enable parallelization of fibres.
The carding machine is supplied with cotton flocks through FBK ducts continuously.
The cotton then traverses through the rollers. The material is fed inside with the help
of feed roller which is located above the feed plate. The feed roller is followed by the
licker-in cylinder.
There is a licker-in undercasing and back plate below and in front of the rollers
respectively. Undercasing is a perforated plate which is responsible for collection of
the waste removal from the card. Back plate is positioned between the licker-in and
cylinder. Front plate is positioned between cylinder and the doffer. Both have spikes
and perform the same function as that of the set of cylinder and flats.
Flats are clothing on the rollers which is in the form of spiked belt. There are 102
flats of which about 42 are in working position at time of contact with cylinder.
Cylinder moves very fast as compared to the flats. Due to this movement, the best
fibres are straightened, made parallel and opening and cleaning is performed.
The back plate and front plate reduces the loading on the cylinder. The voids
between the cylinder, licker-in and cylinder, doffer are thus covered by front and
back plates.28
The cylinder is having the main function of opening and cleaning the fibres.
The main function of the doffer is to collect the fibres from the cylinder and deliver
them in the form of a web. The function of the licker-in is breaking and opening of the
tufts of cotton and pass them onto the cylinder without retaining any of them.
To get optimum performance from the various elements of a card, it is essential to
use the right type and right combination of wire clothing. The metallic wire particulars
which could influence the carding process are: wire width, wire point density, tooth
angle, shape and height.
Carding performance can be improved by increasing the number of teeth cross wise
along the width of the card. This has led to the development of finer rib wires. The
doffer is clothed with a wire which has a higher trapping and holding power than the
cylinder wire. Thus it has a greater point density than cylinder wire.
29
Carding Machine
Machine Specifications
Cylinder Speed 450-500 rpm
Licker-in Speed 1100-1200 rpm
Doffer Speed 25-30 rpm
Flat Speed 22-25 cm/min
Cylinder Diameter 1290 mm
Licker-in Diameter 250 mm
Doffer Diameter 500 mm
Can Diameter 24”
Can Height 42”
Technical Specifications
Linear Density of Lap Fed 400 gm/m
Rate of Feed 500 gm/min
Length of Sliver/Can 5500 m
Weight of Sliver/Can 26 kg
Linear Density of Sliver 4.8 gm/m
Production/min 85 m/min
Production/hour 5100 m/hr
Production (kg/hr) 25 kg/hr
30
CARDING EFFICIENCY AND BREAKAGE MONITORING
DK 780 Card Efficiency
Date Shift (%)
Morning Evening Night
7/12/11 72 85 97
8/12/11 99 96 96
9/12/11 98 97 94
10/12/11 86 98 96
11/12/11 82 96 99
12/12/11 88 97 97
13/12/11 76 97 83
14/12/11 80 62 94
15/12/11 46 95 98
C- 4 Card Efficiency
Date Shift (%)
Morning Evening Night
7/12/11 56 96 95
8/12/11 98 96 85
9/12/11 93 95 95
10/12/11 66 93 89
11/12/11 92 93 90
12/12/11 89 70 95
13/12/11 74 94 93
14/12/11 76 90 98
15/12/11 37 88 98
As observed in the above tables, the maximum efficiency is in the night shifts.
31
PRE-COMBING
Within the overall spinning process, the combing operation serves to improve the
raw material. Its use in the production of medium, medium fine and fine yarns
enables a positive effect to be exerted primarily on the following yarn characteristics:
Yarn evenness
Yarn strength
Cleanliness
Smoothness
Visual appearance
Elimination of short fibres produces an improvement mainly in the staple length of
the fibre, but it also affects the fineness of the raw material. Since noil is on average
finer than the original raw material, the micronnaire value of the combed sliver is
slightly higher than that of the feed stock. The various machines used are:
Sliver Lap Machine
Manufacturer: Lakshmi
It is the preparatory process for combing. The basic purpose of this machine is to
mix different card can slivers, for homogeneous mixing to ensure uniformity among
the fibers. It is used to convert the leading hooks into trailing hooks. It also eliminates
wastes. Drafting arrangement – 4/6
32
Machine specifications:
Linear Density of Sliver Fed 4.8 gm/m
Rate of Feed 75-120 gm/min
Weight of Lap Delivered 10.45 kg
Weight of Bobbin 1.25 kg
Net Weight of Material 9.2 kg
Length of Lap 150 m
Linear Density of the Lap 61.33 gm/m
Time taken for one Lap 150 seconds
Delivery Speed 60 m/min
Delivery in gm/min 3679.8 gm/min
Production in kg/hr 220.74g/hr
Ribbon Lap Machine
Manufacturer : Laxmi
It the second step in the pre-combing process. In this machine the fibers are evened
out.
Unilap machine
This machine performs the combined function of sliver lap and ribbon lap. It’s major
advantage is that it takes less time than the two machines combined.
33
Production of ribbon laps
COMBING
Manufacturer: Lakshmi Rieter
Model: E7/4
Number of Machines: 9
The main objectives are:
Elimination of short fibres
Elimination of remaining impurities
Elimination of large proportion of neps
Straight and parallelization of fibres
The input of this machine is 8 laps. The waste of coming is termed as “noil “.
The lap is passed through a top comb which has got 26 needles or pins per cm. The
function of this top comb is to catch the short fibres out of the lap. It is followed by
another brush roller which consists of plastic bristles on its surface to catch the fibres
flying around. After the combing action, the laps pass through three sets of rollers, of
which top ones are covered with rubber and bottom ones are made of steel. The
material then passes through a condenser acting as a guide and calendar roller to
form a sliver. Top clearer is present in the machine to take care of the fly being
generated.
Machine Specifications:
Number of Heads 8
Length of Machine 5.169 m
Width of Machine 1.318 m
Loading of Rollers Pneumatically
Can Diameter 18”
Can Height 40”
34
Technical Specifications:
Noil Percentage 8-25%
Feed Lap Weight 62.5 gm/m
Feed Lap Width 300 mm
Feed Lap Diameter (max) 450 mm
Delivery Speed 32 m/min
Length of Sliver in One Can 4000 m
Time Taken for One Can 125 minutes
Output/Machine 16-40kg/hr
Nips/min 300
35
Combing Machine
COMBER PRODUCTION MONITORING
Year Average Production (kgs)
2006-07 7925
2007-08 7304
2008-09 7205
2009-10 7130
April 2010
May 2010
June 2010
July 2010
August
2010
Septem
ber 2010
October
2010
November
2010
December
2010
January
2011
Febru
ary 2011
March 2011
5500
6000
6500
7000
7500
8000
COMBER PRODUCTION MONITORING
Average Production
Average production for the year 2010-11 is 6947kgs. It is observed that the
production per year has been decreasing every year.
36
DRAW FRAME
Manufacturer: Lakshmi
Manufacturer: RIETER
The main objectives are;
Parallelization and equalization of fibres.
Doubling
Blending
Removal of hooks
Reducing the co – efficient of variation among the fibres
There are two types of drawframes:
Single head: in which one can is formed from doubling of 6 slivers.
Double head: in which two cans are formed. Each can is from doubling of six slivers.
Main features of RSB drawframe are:
It is equipped with automatic can changer system.
It features an autoleveller. A particular fineness value for the sliver is being set in
the machine. Variation of ±
(1-5) % from the reference value, for a set time, say 3 sec, is sensed by the
displacement sensor. The sensor converts this variation into the pulse form at sends
the signal to control the feed accordingly. If the thickness is increased, feed is
reduced and vice-versa
It is equipped with top and bottom stripper for cleaning top and bottom roller.
37
Machine Specifications:
LDO/6
Number of Deliveries 2
Can Changing System Automatic
Roller Weighing Pneumatic
Calendar Rollers Weighing Pneumatic
Can Diameter 18”
Can Height 40”
Top Roller Diameter 38.2 mm
Calendar Roller Diameter 62 mm
RSB 851
Delivery Speed 250-750 m/min
Rate of Feed 20-50 gm/min
Top Roller Diameter 39.2 mm
Can Changing System Automatic
Delivered Sliver Weight 4.8-4.92 gm/m
Comparison between RSB 851 and LDO/6
S.
No.parameter RSB 851 LDO/6
1. Number of Deliveries Single Double
2. Can Changer Automatic Automatic
3. Creel Driving negative Positive
4. Delivery Speed (max) 800 m/min 500 m/min
5. Creel Capacity 8 16
6. Number of Doublings 8 8
38
SPEED FRAME (Simplex)
Model no. – LF-1400 A
Manufacturer – Lakshmi (LMW)
The speed frame performs three major functions:
Drafting: it is the process where the sliver is attenuated by means of exerting
a pull on it with sets of rollers. This process ensures that the sliver increases
in length and the mass per unit length is decreased.
Twisting: it is the process where the attenuated sliver is given rotational
twists by means of the rotatory movement of the spindle
Roving: it is the output of the speed frame. It takes a highly reduced
thickness (mass per unit length) in comparison of the sliver. The roving is
stored on bobbins and these forms the feed package for the ring frame.
The existence of the speed frame is justified by the fact that the sliver cannot be fed
directly to the ring frame, firstly due to the very high draft requirement at ring frame
and secondly, due to the very large space requirement in ring frame section.
Therefore, the need for the speed frame is to impart draft to the sliver to prepare it
for the ring frame and twist to provide strength to roving.
Main parts of speed frame:
Creel – Here, the cams carrying the D.F. sliver are being placed. The function
of creel is to let the sliver reach the drafting zone, without any obstruction the
drafting zone, without any obstruction. The drafting zone, without any
obstruction, the main parts of creel are as follows:
Creel rollers: it consists of sliver guides, which rotate with the help of creel
roller.
Sliver guide: sliver guide shouldn’t be worn out so that the sliver doesn’t get
abraised due to friction.
39
Drafting zone – this is the main portion of the machine, where the thick sliver
is converted into thinner one by applying appropriate draft. Its main parts are
as follows:
Sliver guide: the sliver from the creel reaches first to the sliver guide of the
drafting zone. This guide is located on a traverse plate. Its size and color
varies acc. To the sliver hank. The guide shouldn’t be worn out and no cotton
fibres should be trapped in between.
Bottom drafting rollers: there are three rollers made of steel arranged at
equal distances according to the length of the machine:
1. front bottom roller
2. middle bottom roller
3. back bottom roller
All the other parts of the machine which are required to provide draft to the
sliver, rotate with the help of these rollers.
Nosebar plate and spacer – In between the front and middle bottom roller,
lies a plate which is called nosebar plate. On this plate lies a square shaped
piece made of Al, which is called spacer. The size of the spacer varies
according to the roving hank. Its size – no.(in mm) is mentioned over its
surface itself. This spacer decided the gap between the 2 aprons. In a
machine, all the spaces should be of equal size and any roving should not be
made without spaces, as it would affect the quantity of the roving
Bottom and top apron – Bottom apron runs between bottom roller, nosebar
plate and tension pulley. The tension pulley provides proper tension to the
apron. In between these two aprons, the sliver, after drafting, forms the roving.
That is why, it is very important that the aprons should not be worm out or
loose. They should be cleared up, time – to time. So that they could run
without any obstruction, otherwise the no. of breakages can increase and the
quality can deteriorate.
Top arm – The arm placed over the bottom rollers is called top arm, which
consists of 3 rollers: front pair, back pair and cradle rollers. The top arm
presses the top rollers over the bottom ones, then pneumatic pressure 40
because of which the slivers, after passing through the drafting zone, take the
form of roving. The top arm should be cleaned regularly for good quantity.
Spindle parts –
Spindle: spindles are positioned in front of the top arm on a rail. Spindles are
run through gear mechanism. Bobbin and flyer are placed on the spindle. To
rotate the bobbin separately, the bobbin rail also consists of gears. The
bobbin rail move up and down through ‘building motion’ because of which the
roving gets wound over the bobbin.
Flyer: the part which helps to wind the roving over the bobbin is call flyer. A
‘twist master’ is placed over it, which helps in imparting twist to the roving,
which comes from the drafting zone. There is a finger on one side of the flyer
which keeps the roving under pressure while it is being wound over the
bobbin.
Separator: the steel plate lying between drafting zone and flyer is termed as
separator, which prevents the mingling of broken roving with the ones,
nearby. Machine shouldn’t be run when separator is down position.
Gearing parts: gears are placed on the right side of the machine, which are
responsible for providing necessary motion to the different necessary motion
to the different parts of the machine.
Fan: it is placed on the left side of the machine. There is a separate motor for
running the fan. Below each delivery lies a suction pipe, whose other end
goes to the suction duct. Inside the duct, there are 2 photocells. Because of
the fan, suction is generated in the whole duct. Because of which broken
roving gets sucked inside. The moment, this roving passes in between the 2
photocells, the machine stops automatically. The waste of the fan must be
cleaned time to time.
41
FAULTS OCURRING IN SPEED FRAME
The main faults that occurs in the output of speed frame are as follows
A. Double roving: when, one roving breaks and clings to the surrounding roving,
while the machine is in running position.
Reasons:
Less amount of pressure in the suction tube.
The suction tube gets clogged because of cotton fluff
Separator is not positioned correctly
42
Simplex Machine
B. Cuts in the roving:
Reasons:
Cuts in the sliver during drawframe only
Incorrect – pressure of the top arm.
Rubber of top roller is having cuts or worn out
Worn out apron
Worn out twist master and flyer finger.
C. Undrafted roving:
Reasons:
Less pressure from top arm
Incorrect setting of temperature and humidity
Incorrect setting of break draft, gauge, spacer etc. according to the
required count.
Hard bobbin:
Reasons:
Less pressure on back rollers therefore thick roving
high tension on the roving
more twist in the roving than the required amount
D. Soft bobbin:
Reasons:
less tension in the roving
less twist in the roving than the required amount
43
E. Flied and fluffed bobbin;
Reasons:
in calculation of fly and fluff from the surroundings into the roving
uncovered draw frame cans
not cleaning the racks and trolleys where bobbin are to be placed
F. Stained bobbin:
Reasons:
not cleaning the grease or oil on the machine during maintenance cleaning
uncleaned hands of the workers
dropping the bobbins on the floor
Machine Specifications:
Number of Spindles 120
Bobbin Length 32 cm
Bobbin Diameter 4.8 cm
Flyer Speed (max.) 1400 rpm
Delivery Speed (max.) 30 m/min
Full Bobbin Weight (max.) 3 kg
Drafting System 3/3
Technical Specifications:
Linear Density of Sliver Fed 4.8 gm/m
Delivery Speed 18 m/min
Length of Roving on one Bobbin 2000 m
Production/hour/spindle 1080 m/hr
Production in kg/hour/spindle 0.772 kg
Waste Percentage 1%
TPI 0.96
RING FRAME
44
Manufacturer: Lakshmi Reiter
Model: DJ/5
Number of Machines: 24
In the Ring Frame department, yarns of required count are made from the bobbins.
Here, draft is being provided with the help of rollers and then twist is being imparted
with the help of spindle wound, side by side. So, the yarns made by this method are
wound on the ring bobbin.
Parts of a Ring Frame Machine are as follows:
Creel – this is the top most part of the machine where the speed frame bobbin
is mounted. The various parts of the creel are :
Bobbin holder: on the bobbin holder, the simple bobbin holder, the simple
bobbin is mounted. It is denoted that the bobbin is mounted properly and the
holder is not clogged. If it is so, the roving will not be fed properly and there
might be some tension which can cause breakage and neps formation.
Creel rod: it is present between the drafting and the bobbin holder. It acts as
a guide for carrying the roving. Roving should always come from above the
guide rod.
Drafting Zone – This is the most important Zone of the machine. Here the
roving is stretched to from the yarn. Its various parts are :
Roving guide: it is used to guide the roving to the centre of the roving might
move outside the roller surfaces and generate waste. It is mounted near the
back roller.
Bottom rolls: the machine has three bottom rolls. On top of the set of bottom
rolls, there is the top arm. The top arm also has 3 rollers and a cradle. The
cradle has spacers.
Bottom apron & Top apron: bottom apron is mounted on the middle roller
and cradle of the bottom roller set. Top apron is mounted on the middle roller
and cradle of the top arm. On these aprons, the roving thread opens up to
take the form of final yarn.45
Spindle Zone –
Spindle: This is an important part of the machine which rotates with the help
of the spindle tape. This always rotates in the centre of the ring and the
bobbin is lifted on it. If the spindle tape is not tightly, attached the spindle may
stop.
Ring and Ring Traveller: it is a metallic ring on which the traveller holds the
yarn and moves along the periphery. The spindle moves up and down and
hence the bobbin gets filled.
Laput hook and laput rail: before the thread gets wound on the bobbin it
passes through the laput hook. It should have a proper gauge.
Gearing Zone – this has all the gears and wheels which need to be oiled and
maintained. This area should always be kept covered to prevent the entry of
fluff.
Fan Zone – this zone consists of the main motor and the fan. Because of the
rotation of the fan at a high speed, suction is generated and waste is sucked,
which gets collected in the waste box. When this box gets filled completely, all
the waste should be taken out from the box and it should be cleaned so as to
avoid any chance of jamming in the fan and parts malfunctioning.
Jockey Pulley and Drum Pulley Zone – the setting of the jockey pulley
should be correct, otherwise the tape bar would become out of track. It should
not get jammed, so it is cleaned from time to time.
Overhead Blower Zone – the pressure with which the blower throws the air
should not be blocked with fluff and they should be properly set, otherwise it
would affect the quality.
46
Different Colour Bobbins and Their Importance:
In ring frame, bobbins of different colors are used like: red, yellow, blue, white
etc. the color of bobbin varies according to the count of yarn. While the
production with bobbins of one color is going on, the bobbins of other colors
should be used, otherwise the mixing of various varieties will occur and quality
will get deteriorated. The weight of speed frame bobbin varies from 1- 1.5 kg,
while that of ring frame varies from 60 – 65 gm.
47
Ring Frame
Main Faults That Occur In Ring Frame:
A. BOBBIN FAULTS :
(i) Ring cut and black bobbin: Sometimes, the thread gets cut by the ring and
sometimes it gets cut by the ring and sometimes it gets blackened because of
the ring. The main reasons of its occurrence are:
Improper setting of bobbin over the spindle because of the
accumulation of hard waste over the spindle
Occurrence of double roving in the speed frame bobbin
Slight displacement of ring of ring rail.
(ii) Bottom spoiled bobbin: if the yarn in the bobbin comes out from the bobbin
and gets entangled then it is called bottom spoiled bobbin. Its main reasons
are as follows.
Improper setting of spindle
Improper setting of bobbin on spindle due to carelessness
Improper setting of bobbin on spindle due to tight bottom portion of the
bobbin
Improper setting of the reel rail
(iii) Over filled bobbins: if the yarn from the upper position of the bobbin gets
entangled, then it is called over filled bobbins. Reasons:
Using small bobbin than the required size.
The machine still keeps on running even when doff has been achieved.
(iv) Soft bobbin:
less twist in the yarn because of rotation of lower speed due to any
reason.
Less tension of traveler acc. to the count.
(v) stained bobbin : reason :
not wiping off the oil & grease.
Uncleaned hands of the worker.
48
B. YARN FAULTS:
(i) Double roving:
Mingling of broken roving with the neighbouring rovings of the creel.
Malfunctioning of suction tube because of blockage due fluff.
(ii) Weak yarn:
Occurrence of single roving in the speed frame bobbin.
Loose tape
Cut tape
(iii) Yarn with fluff:
Inculcation of fluff from the environment into the yarn.
Improper cleaning of the drafting zone & other parts.
Dirty speed frame can/drum.
Uncovered drums/cans.
Malfunctioning of overhead blowers.
(iv)Yarn slub: yarn should be uniform in diameter. But at some places, the yarn
become fuller, where twist becomes less and the strength of the yarn reduces;
which is called slub.
Improper pressure from the top arm.
Apron which is being cut.
Improper setting of the spacer.
(v) Neppy yarn: In the blow room, due to the formation of bunches of fibres
which occur on the surface, this defect arises. To regulate this, care is taken
at blowroom, carding and combing department.
(vi)Yarn with thick and thin places: the yarn thickness should be uniform
everywhere, but when thick & thin places arise in the yarn, with the length
varying from 8-10 mm, then such a yarn is called defected. These defects are
measured by uster machine per Km. eg. + 50% thick place means that the
thickness of the fault is 50% more than the actual thickness. Similarly, -50%
thin places imply that the fault is 50 % less than the actual thickness of the
yarn. The yarn with the thin place has comparatively lesser strength.
49
(vii) So, it can break and create more waste and effect the production &
quality adversely. Its main reasons are as follows :
Improper pressure of the top rollers.
Apron being cut or dented.
Improper setting of the top arm.
Incompatible size of spaces in relation to the count.
Draft applied is not in accordance with the count.
The yarn realisation of the cotton fibres comes approximately 87 kg for carded yarns
and approximately 70 kg for combed yarns. This is so as the combing process
removes the short fibres. The noil % (waste removal %) for the combing process is
around 17%.
The bobbins from the ring frame m/c are collected in containers after their doffing
point has reached. In each container, a doff slip is put. This slip is important as it
contains the following details:
Spindle no.
Machine no.
Count
Time
Date
Name
This is important as the person loading the bobbins for identifiable faults. Also they
are important for count identification. After this, the trolleys are sent to the Autoconer
Machines. This has the function of forming bigger packages in the form of cones
which can be used for doubling and then twisting on the T.F.O.
50
Machine Specifications:
Spindle Height 240 mm
Spindle Diameter at Top 11 mm
Spindle Diameter at Bottom 15 mm
Distance Between Two Spindles 70 mm
Length of Separators 140 mm
Number of Spindles Per Ring Frame 448
Spindle Speed (max.) 18000 rpm
Delivery Speed 18 m/min
TPI 21.06/19.58
Production till 11/12/11 for the year 2011
(Tonnes)Manpower/Shift
Ring Frame Production 11.56 84.01
Ring Frame Utilization(%)
93.42 84.01
51
January February April May June July August0
2
4
6
8
10
12
14
16
11.711.9
12.6 13.4 13.9 14.2
Ring Frame Production/Month(Tonnes)2011-12
Ring Frame Production
52
WINDING SECTION
Yarn produced in the ring frame in the form of bobbins is taken into the winding
section for the formation of large package which is easily transported and various
faults are removed during the winding operation such as thick places, thin places
and neps.
After winding, the package should not contain the faults. The strength, elongation at
break point and appearance should not be altered and the quality of splicing should
be good. The weight of the cone produced is 2.05 – 2.45 kg and 1.25 kg as per
demand.
Manufacturer: Schalfhorst
Model: 338
Number of Machines: 4
53Autoconer: For bigger yarn packages
The bobbins are attached on the spools and when the bobbins get exhausted, new
bobbin is attached manually after every bobbin change, splicing is done by the
machine for the identification of the counts of yarns. The machine follows the
following detection mechanism:
Electronic sensors which detect the yarn breakage and stop the machine.
This is done through capacitors.
Machine Specifications:
Number of Drums on the Machine 60
Number of Bobbins on the Creel 5
Distance Between Two Spindles 13”
Drum Speed 1300-1600 m/min
Splicing Pneumatic
Magazine Capacity 6
54
Inspection of cone in the Autoconer
January February April May June July August86.4
86.6
86.8
87
87.2
87.4
87.6
87.8
88
88.2
87.0587.07
87.93
88.188
87.74
Yarn Realization: Carded (%)2011-12
Yarn Realization
January February April May June July August70.4
70.5
70.6
70.7
70.8
70.9
71
71.1
70.6670.68
70.89
70.8
71
70.67
Yarn Realization: Combed (%)2011-12
Yarn Realization
55
January February April May June July August26.5
27
27.5
28
28.5
29
29.5
30
28.2
29.68
28.87
27.7
29.3
28.92
Average Yarn Count2011-12
Yarn Count
In this section the cones are kept under UV Light for inspection. This is one of the steps in detecting any yarn faults and difference in colour of the grey yarn.
56
Inspection of cones under UV light
CONDITIONING
In VSGML, conditioning of the cones is done manually, i.e., room conditioning. The
moisture percent in the cotton yarns comes out to be 7.4%. The material after
conditioning remains for 15-20 minutes outside the conditioning room and final
packaging is done in cartons or pallets according to the requirement.
To avoid the loss of moisture from the cones, two humidifiers are provided in the
packing room. Because of these humidifiers, there is an additional gain of moisture
in the yarns on the cones. Increase in the moisture content of the yarn increases the
yarn realization; therefore, the conditioning of the yarns is necessary.
Following are the main objectives of conditioning:
Imparting strength to the yarn
Imparting uniformity to the yarn
Imparting evenness to the yarn
Increasing the moisture content in the yarn
Increasing the yarn realization
57
Conditioning room for yarn where sprinklers impart moisture before the cones undergo conditioning in the Xorella Machine.
58
Xorella Machine: A set of cones are put in the machine for moisture regaining
PACKING SECTION
According to the requirement of the buyer, the yarn package is made as cone or
cheese form. Further the yarn packages are packed in the following ways:
Palette Packing:
This is done on reusable palettes which are wooden stands on which the
cones are kept in layers. After each layer of cones a cardboard is placed on
which further cones is placed. The total weight of the palette is approximately
750 kg. This palette packing is more cost effective as the cost incurred is only
of the cardboard sheets and plastic sheets. The following description is
mentioned on each palette.
Count
Lot no.
Net weight
Gross Weight
Excise no.
Date
59Palette Packing
Carton Packing:
The cones can be packed in cartons. The following description is mentioned
on each carton.
Description
Count Ne
Excise no.
Carton no.
Gross weight
Net weight
Lot no.
60
The carton packing is less cost effective as the cartons are not reusable
PROCESS FLOW OF WORSTED SPINNING
61
Mixing
(Laydown)
A variety of fibers, depending upon the output, are mixed so as to make them uniform.Sandwich laydown takes place wherein a 60:40 ratio of regular and high bulk fiber is laid.
Willowing
Input: Small bale tuft, Output: Open fiber tuft
Carding
Separation of each and every fiberSliver preparationInput: Open sliver tuft, Output: Card Sliver
Levellin
g (Gill Box)
Increasing uniformity of fibersParallelising the fibers
Simplex Machine
Input: Uniform Sliver, Output: Roving
Ring Frame
The draft is made according to the count of rovingYarn is made out of roving.
Autoconer
Removal of unwanted deformities of yarn and converting the ring frame yarn into a bigger package
Cheese Winding
For plied yarns
TFOTwo For One twister where plied yarns are twisted in order to achieve the output.
Reeling
Either the yarn is packed after this or it is sent to the dyeing house in the form of hanks.
WILLOWING
Number of machines: 1
Manmade fibres do not require any cleaning so they are directly made into cards
from their fibre tufts. The primary purpose of the willowing machine is to open up the
fibre tufts into smaller tufts and to mix up various kinds of fibres.
This opening is accomplished by passing the material between two beaters. After
this, material is transported to the cards through a network of pipes.
Unlike the cotton spinning process, in the worsted process (where we to have to
process only synthetic fibres), there is no need of cleaning the fibres as they are
manmade.
62
Synthetic fiber is fed in the Willow Machine for opening and mixing
CARDING
Manufacturer: Thibeau, Tatham and Hergeth
Model Number: CA-6
Number of machines: 5
The carding process aims at forming a sliver. The fibres are individualised by means
of an extensive arrangement of numerous cylinders. These are arranged so as to
open up the fibres to the optimum and ultimately to separate each single fibre.
The carding machines used are “Thibeau” (manufacturer) aerofeed cards. These
cards are fed by means of pipes, which are connected, to the willow machine.
Inside these machines, exists a complex arrangement of cylinders of various sizes
and this arrangement is designed to optimally open the fibres. The output of these
machines is a sliver, i.e., a loose rope of totally individualised fibres. This sliver is
stored in cans for transportation to the gill boxes.
Weight of Card Sliver 30-35 kg
Fibres Used 100% Acrylic, Nylon, Polyester and Blends
Capacity of the Machine 65-75 kg/hr
63
Slivers of synthetic fiber coming out of the Carding Machine
LEVELLING (GILL BOX)
Manufacturer: Schlumberger
Number of Machines: 13
The gill box is the equivalent of the draw frame used in the cotton spinning process.
Here the gill box is used to form tops or balls, which form the feed package for the
next stage. The gill box also combs the fibres to achieve the maximum parallelisation
of fibres. In addition, the gill box compresses a few card slivers into one sliver so it is
used for blending different kinds of material into one sliver.
In the gill box, the combing is done at the “faller” arrangement and the delivery rolls
do the calendaring. Thus the sliver produced is a blend of many slivers, i.e., is a
blend of different types of materials. According to the properties of the material it
may be given more than one passage through the machine. The sliver produced can
be stored in cans or be made into tops as per the requirement of the next process.
64
Parallelization of fibers in the Gill box
No.of Faller 2 x 72
Delivery Cans 1, 2 or 4
Can Specification 800 x 1100 mm
Diameter of Top Roll 80 mm
Bottom Delivery Roll Diameter 60 mm
Drafting Range 4.1- 11.9
Number of Cards fed to the machine 8
Capacity GN type: 800-1000kg/shift
GC type: 2000-3000 kg/shift
65
Drafting inside the Gill box: The sliver becomes thinner and finer
SIMPLEX
Manufacturer: NSC
Number of Machines: 3
Model Numbers: FMV-32 (2 numbers), FM-7 (1 number)
The speed frame performs three major functions:
Drafting: it is the process where the sliver is attenuated by means of exerting
a pull on it with sets of rollers. This process ensures that the sliver increases
in length and the mass per unit length is decreased.
Twisting: it is the process where the attenuated sliver is given rotational twists
by means of the rotary movement of the spindle
66
Simplex Machine
Roving: it is the output of the speed frame. It takes a highly reduced thickness
(mass per unit length) in comparison of the sliver. The roving is stored on
bobbins and these forms the feed package for the ring frame.
The existence of the speed frame is justified by the fact that the sliver cannot be fed
directly to the ring frame, firstly due to the very high draft requirement at ring frame
and secondly, due to the very large space requirement in ring frame section.
Therefore, the speed frame imparts draft to the sliver to prepare it for the ring frame
and twist to provide strength to roving.
Machine Specifications:
Number of Drafting Elements 12
Drafting Range 9-26
Maximum Delivery Speed 200 m/min
Number of Cans Fed 24
Feed Roll Diameter 40 mm
Delivery Roll Diameter 25 & 50 mm
Capacity 100-200 kg/spindle/hr
Maximum Rubbing 1100 cycles/min
Bobbin Length 240 mm
Tension range between feed roll and
draft apron
0.3% to 7.8%
Tension range between rubbing apron
and winding roller
0% to -11%
Tension range between draft roller and
rubbing apron
0% to 6%
67
RING FRAME
Manufacturer: Ishikawa
Number of Machines: 26
This is the stage where the yarn is finally formed. The ring frame gives the final draft
and the twist to the roving received from the speed frame.
The mechanism used consists of three sets of rollers for drafting and spindles for
providing twist to the yarn.
68
Ring Frame
The process is carried out with the help of rollers and the roving is drafted to a
requisite mass per unit length. It also imparts the required twist to the yarn through
the rotation of the spindle. The spindles have a very high rate of revolutions per
minute. This and some other criteria are adjusted so as to acquire a definite level of
TPI, i.e., twist per inch length of yarn.
The input in the ring frame is the roving received from the speed frame. This roving
is ultimately converted to “yarn”.
Machine Specifications:
Number of Spindles 400
Drafting System 3
Bobbin Length 220 mm
Spindle Length 240 mm
Capacity 12-15 metric ton/day
69
AUTOCONER
Manufacturer: Jehlafhorjt and Murata
Number of Machines: 6
The bobbins from the ring frame m/c are collected in containers after their doffing
point has reached. In each container, a doff slip is put. This slip is important as it
contains the following details:
Spindle no.
Machine no.
Count
Time
Date
Name
This is important as the person is loading the bobbins for identifiable faults. Also they
are important for count identification. Each order has a specific colour bobbin allotted
to its lot. After this, the trolleys are sent to the Autoconer Machines. This has the
function of forming bigger packages in the form of cones which can be used for
doubling and then twisting on the T.F.O.
70
Machine Specifications:
Manufacturer Jehlafhorjt
Number of Machines 5
Number of Heads in one Machine 60
Diameter of Yarn Guide Drum 95 mm
Width of Splicing Chamber 3.5 mm
Package Diameter (maximum) 326 mm
Capacity 8-20 kg/spindle/shift
71
Splicing is done side by side as the bigger packages are formed in the Autoconer
TFO
Manufacturer: Veejay Lakshmi
Model Number: VJ 160 HS
Number of Machines: 43
This machine is used for doubling of yarn. The single yarn in the cone form is
converted into cheese. Two, three or four cones can be used to double the yarn
without applying any twist. This doubled yarn is wound on cheese.
This machine operates on the two for one principle of applying twist. The yarn is
gripped at two points during twisting before being wound on the cones.
The yarn packages in the form of cheese are kept in the containers of the TFO
twister. The yarn is threaded and is gripped at one point below the spindle and at the
other point , which continuously rotates and inserts twist. The twisted yarn is wound
on the cones. The twist is varied by changing the speed of rotating spindle in the
container which grips the yarn. After the cones are removed from the TFO, the
following data is mentioned.
TPI
Cone Weight
Customer
Count
M/C Number
72
Machine Specifications:
Number of Spindles 168
Number of Spindles/Section 6
Spindle Gauge 254
Pot Diameter 168 mm
Twist Range 2.5-4.3 TPI
Package Type Cheese
Maximum Length of Package (mm) 170
Spindle Speed 12000 rpm
Stop Motion Mechanical
Machine Width 1.1 m
Machine Length 23.3 m
73
Two For One Twister
CHEESE WINDING
Manufacturer: Saurer Allma
Number of Machines: 4
This step is carried out in order to increase the twist of the yarn. The cheeses
produced in the autoconer are wound onto bobbins using this machine. A total of 116
bobbins are produced at one go.
74
Cheese Winding Machine
REELING
This is the process which is carried out in order to convert bobbins to hanks
depending upon the customer’s request. Each machine has 44 heads for preparing
44 hanks. Weight of the hank also depends upon the customer’s specifications.
Number of Machines: 18
Time taken for winding 44 hanks: 10 minutes for hanks of 150 gm each
75
Reeling is taking place in the Hank to Cone section
PACKING
For worsted spun yarns, packing is done in three ways:
Hank Packing (Automatic packer)
Cone packing (Palette)
Carton Packing
76
Autopacker
FANCY YARNS
Fancy yarns or novelty yarns are typically made of two or more strands which are
produced to provide decorative surface effects. Based on the purpose of yarn, each
strand is referred to as the base yarn, the effect yarn or the binder yarn.
The base yarn provides the structure and strength, the effect yarn creates a
decorative detail like loops and knots and the binder yarn is used to tie the effect
yarn and the base yarn if binding is necessary.
77
L-R: Flurry Yarn, Boucle Yarn, Loop Yarn
Fancy yarns in VSGML are produced by four machines:
NEEDLE SPINDLE MACHINE
The effect yarn is cut by a blade so as to produce the flurry effect after which it is
twisted with the base yarn.
78
The triangular blade in the Needle Spindle Machine is used to produce the Flurry effect
Production of Flurry Yarn
CROCHET MACHINE
This is a knitting machine which works on the principle of warp and weft yarn. The
yarn is firstly knit and then it is cut by the blade in order to create effects like feather
and knop. It is also used to make laces.
79
Crochet Machine
HOLLOW SPINDLE FANCY TWISTER - EHP MACHINE
EHP machine is a multi-purpose machine which is capable of producing most of
the effects. Loop, caterpillar, boucle, slub and knop are some of them. These
effects are created by setting the speed of the drafts according to the effect
required. For example, for a loop effect, the speed of the draft for base yarn
would be lesser in comparison to the speed of the draft of the effect yarn. This
way more yarn is wound around the base yarn in a shorter period of time creating
loops.
80
Hollow Spindle Fancy Twister
ESP MACHINE
In this machine, one yarn comes straight passing through the hollow spindle,
which is known as the base yarn, while the other yarn which is the effect yarn is
wrapped around the base yarn by a twister which moves around the base yarn.
SEQUIN MACHINE
In this machine, sequins are added to the base yarn one by yarn or at regular
intervals that are set depending on the requirement. Garlands of sequins are
loaded on the machine while the base yarn is fed from one side. Once the
sequins have been attached to the effect yarn it is twisted along with the base
yarn and finally wound on a cone.
81
Sequins are kept on the top inside a very long inverted tube from where the sequins are fed into the yarn periodically
ASSIGNMENT- 2
82
DYEING
At VSGML, yarn dyeing is carried out. Mostly hank dyeing is done.
BULKING:
Bulking is mainly done to give relaxation to the yarn, which can otherwise create
problem of shrinkage in home laundering.
To attain shrinkage at yarn stage.
To get even and better quality yarns.
To improve running characteristics of material.
Bulking can be done by two methods
Water bulking
Steam bulking
Water Bulking: water bulking is done in a hank machine. The
temperature in the machine is maintained at 80°C. It takes about 10
minutes for bulking of yarns.
Steam Bulking: steam bulking uses autoclave for the bulking process. This process
involves homogenous moistening of materials which reduce electrostatic charge
83
which otherwise, influence evenness of yarn. This is done to get even and better
quality yarn. Also, to improve running characteristics of material. Efficient steaming
enables to achieve homogenous moistening important for proper dye ability.
Manufacturer: STAFFI – R.B. Electronics
Machine Specifications:
Capacity 180 kg
Number of Trolleys in Machine 5
Quantity Load per Stick 2.25 to 3 kg
Limit of Vacuum Pressure 0.5 kg/cm²
Limit of Steam Pressure Not more than 0.8 kg
Limit of Temperature 98°C
84
Bulking of Reels inside the Autoclave
HANK DYEING MACHINE- CABINET DYEING:
Number of Machines: 32 (3 are sample machines)
Manufacturers: Tung-Shing, Lorris Bellini, Tekst
It is suitable of processing natural fibers, synthetic and blends at temperature lower
than 100°C. Scouring, bleaching, dyeing and washing are processes done at boil, by
loading once. There is belt driven speed system to suit different kinds of yarn. The
industry has machines of 3 different manufacturers. They differ in their dyeing
capacity, water capacity, water consumption/lot, power consumption/lot, steam
consumption/lot, compressed air consumption/lot and number of sticks.
Machine Specifications:
Number of Carriers/Machine 2
Operating Steam Pressure 5 kg/cm²
Limit of Temperature 102°C
85
Dyed Reels in the Cabinet Dyeing Machine
Main parts of machine
a) Kier
b) Sampling devices
c) Loader
d) Additional tank
e) Cooling water outlet
f) Steam trap
g) Additional tank drain
h) Feed pump
i) Additional flow control
j) Impeller
k) Water drain
l) Pulley
m) Water supply
n) Cooling water inlet direct heating
86
HYDRO EXTRACTOR:
Manufacturer: Minnetti Italia (Officine)
Number of Machines: 6
It is used to remove excess water from hank after dyeing. It works on the principle of
centrifugal force. The time required to hydrate the cotton material is more than the
acrylic as cotton has more moisture regain than acrylic. If cotton is not properly dried
then it may create problems during cone winding.
Machine Specifications:
Capacity 5 machines have 30 kg capacity and 1
machine has 45 kg capacity
RPM of Motor 1450
Cage Drum 690-700 rpm
Quantity Loaded per Batch 30 kg for Acrylic
Cycle Time of One Batch 8 minutes for Acrylic
Standard Productivity 1350 kg/hand
87
Hydro Extractor
DRYER:
Manufacturer: Minnetti Italia (Officine)
Number of Machines: 2 (1 old and 1 new)
Hank dryer is used to completely dry the hanks of yarns after dyeing and
hydroextraction.
Machine Specifications:
Features Old Dryer New Dryer
Number of Hangers 180 210
Temperature 95-105˚C 95-105˚C
Capacity 1 kg 2.75 g
PRINTING MACHINE:
Manufacturer: 5WA (Italy)
Number of Machines: 1
Number of Colour Tanks: 4
This is a new addition to the VSGML dye house for creating yarns with multiple
colours. In this printing machine, roller printing machine is used to carry out localized
dyeing, for giving fancy effect.
88
In this machine, 48 cones are printed at a time. There are mainly 3 rollers:
Furnishing Roller: always remains dipped in colour and transfers colour to the
other roller.
Engraved Roller: Transfers colour to the yarn band and doctor blade here,
removes extra colour.
Pressure Roller: provides pressure to the yarn band. Yarns are dried and
hanks are formed.
89
Printing Machine; Output of one of the Rollers which is then forwarded for heat setting of colour
DRESSING:
Dressing is the main part in the yarn hank processing because in bulking, dyeing,
dyeing etc. the yarns in the hanks are entangled and they create problems during
hank to cone winding. Thus, it is very necessary to dress the hanks after drying as it
makes hank to cone winding operation easier.
90
Dressing is done by one of the workers in Hank to Cone section
DYEING PROCEDURES
There were various dyeing processes going on during our internship period which we
covered. They are explained below:
Process of 100% Acrylic Violet Shade
91
Take 85˚C warm water & water bulking for 10 minutes
Overflow it at 50˚C
Add I.G. Surf, Acetic Acid, Retarder, Softener
Run it for 20 minutes
Add half colour and dozing it for 10 minutes
Run it for 10 minutes
Raise the temperature at 60˚C at 1˚C/minute
add the other half colour and dozing it for 10 minutes
Run it for 10 minutes
Raise the temperature at 80˚C at 1WC/minute
Run it for 10 minutes
Raise the temperature at 90˚C at 0.5˚C/minute
Run it for 10 minutes
Raise the temperature at 99˚C at 0.3˚C/minute
Run it for 10 minutes
Hold the material and overflow it
Drain the material
Process of Acrylic/Nylon Violet Shades
92
Take 45˚C warm water for the material
Add IG Surf, Acetic Acid and run for 10 minutes
Add half colour and dozing it for 10 minutes
Run it for 10 minutes
Then add next half colour and dozing it for 10 minutes
Run it for 10 minutes
Raise the temperature at 99˚C at 1˚C/minute
Hold the material as required
Overflow at 40˚C
Then add 1% wacker finish & 0.5% Formic Acid
Run it for 10 minutes
Raise the temperature at 90˚C at 0.5˚C/minute
Run it for 10 minutes
Drain the material
Process of 100% Polyester Dyeing
93
Take 45˚C warm water for the material
Add IG Surf, Acetic Acid and run for 10 minutes
Add half colour and dozing it for 10 minutes
Run it for 10 minutes
Then add next half colour and dozing it for 10 minutes
Run it for 10 minutes
Raise the temperature at 99˚C at 1˚C/minute
Hold the material as required
Overflow at 40˚C
Then add 1% wacker finish & 0.5% Formic Acid
Run it for 10 minutes
Raise the temperature at 90˚C at 0.5˚C/minute
Run it for 10 minutes
Drain the material
PROCESS FLOW OF HANK TO CONE WINDING
94
Entry of Dyed Material in Hank to Cone Section
Dressing
Loaded on Winding Machines
Hank to Cone Winding
Cones are placed in a trolley
Checking of Cones
Packing
Different types of machine knitting, hand knitting and specialized yarns are
processed on hank to cone winding machines for further processing or to be
delivered to the market. The machines used are:
PS Mettler
Number of Machines: 9
In this machine, paper cone is attached to the adaptor, one side of which is
attached to the spring to hold cone. It is then brought in contact with the revolving
drum.
Machine Specifications:95
Number of Drums on Each Machine 36 (7 machines), 40 (2 machines)
Drum rpm 300
Weight of Cone 1 kg
SSM
Number of Machines: 3
Number of Drums in Each Machine 24
Drum rpm 400
Weight of Cone 2kg
FADIS
Number of Machines: 10
Number of Drums in Each Machine 35
Drum rpm 350
Weight of Cone 2.25 g
96
REELING:
This process leads to the formation of lea (lachhi) from cone and then sent for
packing in lea form.
Name: METRO – Automatic Reeling Machine & Hydraulic Bundle Press
Number of leas formed in each cycle: 44
Weight of each lea: 150 gm
Time Taken for 44 leas: 10 minutes
RAISING:
Raising is a process of lifting a layer of fibres from the surface of the fabric so as
to form a hairy surface on pile. The process imparts a warm and soft handle. It is
the process of raising the fibres from the surface of the yarn according to
customer’s demand. It gives finishing to the yarn that results in:
Bulkiness
Increase in luster
Improved quality
Attractive look
Soft handle
97
PACKING:
Packing in VSGML is done in four forms depending upon the customer’s demand:
Ball
Lea
Bundle
Cone
Ball: yarn balls are either packed with weight 25 gm or 50 gm. Packing can be in jar
or box. Each jar/box may contain 4, 6 or 10 balls
Lea: each lea weighs 50 gm and given a tag. 2 leas of 100 gm are packed in a small
packet. 20 such small packets make one big packet. 0ne carton contains 16 big
packets.
Bundle: this packing has leas of 200 gm and given a tag. 3 kg of such leas make
one bundle. 5 bundles are packed in one packet.
Cone packing: Cones free from faults are with polythene sheets. 2 layers of cones
are packed containing 9 cones in each layer. Bag is stitched and carton of 40 kg is
prepared.
98
Balls are being made in the Automatic Ball Machine ;Lea Packing
99
Manual Ball making and packing
Bundle Packing
EFFLUENT TREATMENT PLANT (ETP)
ParametersResult treated
EffluentOnline Monitoring
on ETP
PPCB Prescribed Limits for Sewerage
pH 8.09 7.59 5.5-9.0Total Suspended
Solids(TSS)[mg/L]
15 - 100
Total Dissolved Solids(TDS)
[mg/L]1240 - 2100
Dissolved Oxygen (DO)
[mg/L]- 3.59 -
Chemical Oxygen Demand(COD)
[mg/L]36 - 250
Biochemical Oxygen Demand
[mg/L]7 - 30
100
101
102
MATERIAL DEPARTMENT
The main function of the material department is to procure the raw material in the
form of bales for the spinning process, packing material, electrical material, electrical
material, machine spare parts, oil and lubricants, fuel and building material,
furniture and fixtures and administration equipments. It helps in providing the various
request made by all the departments in an effective and efficient way so that there is
no wastage of time.
This department ensures that the unit never falls short of raw material wherever
required. The process flow is as follows:
The corporate office at Ludhiana receives orders from various buyers for yarn
of specific count and yarn
The office then allots the units with the function of production needed to be
carried out e.g. if the buyers demand acrylic yarn, the office will provide unit1 with
the amount of yarn count to be produced.
The units then submit their yearly requirement of cotton or other raw material.
Their estimate of requirement is calculated with the ERP system. The ERP system is
fed with all the details like: production per shift and material requirement according to
the count demanded.
The office then deals with cotton sourcing stations i.e. various states in India
and procures cotton from there.
This detail is intimated to the material department at the spinning unit. The
detail includes the number of trucks/ total quantity (in terms of net weight) to be
coming to supply the materials.
Once the details are received, the material department looks after the
receiving, checking, paying for and storing of the bales.
103
WHILE RECEIVING THE MATERIAL:
The following things are needed to be checked while receiving the materials from
trucks.
Whether the material is designated to be supplied to the particular company
or not because here are two spinning companies of the same Vardhman group,
requiring raw material cotton.
Net weight of the bales is cross checked with that mentioned on the slip
carried by the invoice given to the driver. The weight is calculated by weighing the
truck at the time it comes (with the material) and after unloading the trucks.
Quality of the bales – if the bales are darkened in color and dirty, the defect is
brought into notice of the corporate office. Since the material is insured, the office
itself decides to pay the charges before or after claiming the insurance.
Various places from which bales are procured:
Punjab
Gujarat
Madhya Pradesh
Rajasthan
Karnataka
Andhra Pradesh
Various qualities of cotton procured are:
Indian cotton : Shankar 6, J-34
Varieties Cost (Rs. / kg)
Shankar 6 52-54
J-34 46
104
The procurement is done once or twice in a year. But can also be done whenever
required. The season begins from October/November and ends in February/march.
After checking all the above mentioned details, the material is sent to be
stored in the godown.
In the godown, the bales are stored in form of stacks.
Stickers are put on the bales which are used to identify the number of bales
stored.
Bales face is always kept on the outer side for identifying the stickers.
The no. of the bales stored into the stack and the information is entered into
the ERP system.
The details which are fed are the quality of the bales i.e. the variety, number
of bales of each kind station from which they are received.
The bales are pressed bales which have no chance of getting fire.
It is always taken care of that the godowns never fall short of material stored.
105
DISPATCH
The production department submits the requirement of the raw material to the
material department. The variety of cotton and the number of bales is specified.
The godown then issues the cotton bales to the production unit and the
corresponding issue slip is filled.
On an average the production unit requires 300 bales/day.
The issue system is FIFO (first in first out) i.e. the bales which are arriving first
are issued first. The pressed bales can be kept in the godown for long time also as
they are not affected by fire or water.
106
MAINTENANCE DEPARTMENT
The main objective of maintenance department is to eliminate the breakdowns,
maximum utilization of machines operating time, incorporations of new technologies
and engineering development in the basic design of the machines, augmentation of
machine capabilities and optimum expenditures on maintenance function and
activities. This aspect of maintenance function helps in reducing or completely
prevents maintenance efforts during lifetime of the equipment.
It involves various maintenance activity that are to be recorded a year head which
helps in planning of manpower, material and service which are required for the
period. This system helps in analysis of maintenance work measurement, machine
replacement, nature of breakdown and downtimes etc.
There is a review committee comprising of spinning superintendent, maintenance in
charge and his assistants. This committee holds its meeting regularly and reviews
the maintenance performance in the following areas :-
Analysis of breakdowns.
Ratio of downtimes too available operating time.
Ratio of other maintenance hold ups to available operating tome.
Review of maintenance costs.
Review of major replacement.
Review of maintenance function and performance.
Review of training program.
Review of work done by the maintenance personnel.
107
ENGINEERING DEPARTMENTThe objective of the engineering department is to provide uninterrupted good quality
power supply, oil and water free compressed air, healthy and well-maintained
humidified air to the production plant thereby adding value in producing good quality
yarn. It also helps in catering to the needs of colony residents, club and
administration by maintaining safe electricity and water distribution, sewage
treatment plants etc.
INDUSTRIAL RELATIONS DEPARTMENTThe procedure underlines the system and methods relation to the functional
responsibilities of industrial relations department, i.e. manpower planning,
recruitment, time office function, training and development, grievance handling,
welfare and colony administration etc. The system has been designed to provide
better services to the human resource and helping them achieving the quality
standards as required under ISO 9002.
The endeavor of IR department is to promote harmony and industrial pace, fair shop
floor practices and promote good relations with local external agencies.
108
TRAINING DEPARTMENT
Training and development has been regarded as an important tool for the
improvement of skills level, work habits, development of positive attitude of the
worker and upgrading the system. Training and development serves as an important
means for preparing workers for modified performance standards, improvement of
quality of product and reducing absenteeism, accidents and material wastage.
Since training is a continuous and time consuming process and entails much
expenditure thus while designing and implementing training program, due
consideration is given to the organization and workers needs. The activities relating
to workers training are organized in workers training and development center i.e.
Manav Vikas Kendra (MVK), which is within the premises of Vardhman Spinning and
General Mills Ltd. To achieve these objectives more emphasis and importance has
been given to impart a systematic attitudinal and function training to the workers.
Once a positive work culture and attitude is developed the workers shall they be
interested in improving their skills and knowledge. The main focus is on workers
learning and not on teaching them.
January February March April May June July235
240
245
250
255
253255 254
238239
236
Manpower/Day(2011-12)
Average Operators
109
COSTING DEPARTMENT
The marketing department forecasts the quantity of yarn which they can sell and the
production department reports the amount of yarn which the unit can produce. The
costing department then makes the annual and monthly budgets. The budget
includes the following factors:
Labour wages
Raw material
Packing material
Electricity
Transport (raw material and dispatch)
Maintenance cost incurred during production run.
The budget and the production plan are installed in the ERP system which is
transparent. The users can see the activity schedule of the production planning
through various codes specified. The ERP system is also fed by the daily production
details of the units.
The costing department checks the production details through the ERP system
production delays can cause high costs to the company.
The department is given the inputs regarding the count of the yarn to be made, the
total amount of time of dispatch. The department ensures that no ring frame remains
idle or in non working condition during any of the shifts.
The department checks the report for any kind of detensions (detension report) or
stoppages during production. By checking the detension reports the department
comes to know the reason and timing of the machine stoppage. The machine
stoppage has direct effect on the production of the unit. Some serious causes
requiring maintenance department look after are brought into notice and checked.
For any production order running the following is the estimated cost break up in the
percentage.
110
RAW MATERIAL 50 – 55 %
POWER COST 12 – 15 %
These two factors account for the major cost incurred. The department also looks
into the profitability factor. After receiving the order, allotted by the corporate office,
the department decides the time required for the completion. This time is calculated,
as specified earlier, through the machine productivity data available in the ERP
system. The daily production details are checked and thus the order is kept under
track.
It is also to note that the cost of storing the finished good i.e. yarn is incurred. Thus
the dispatch is done within a time of 10-12 days otherwise the working capital gets
blocked.
111
LEARNING OUTCOME
The learning at Vardhaman Spinning and General Mills was indeed a unique one
with a lot to understand and take with us. The major learning outcomes at VSGM
were based on the following points:
Understanding of the different departments working at the factory
Necessary processes to be carried out before final delivery
Inevitable constraints for any process
Understanding of spinning, problems and their solutions
Understanding the importance of workforce and results of absenteeism on
production
Understanding the machine effectiveness and addressing their maintenance
issues
The process flow of Production Department and the steps involved
The above areas of understanding made us more aware of the spinning
operations, weaving operations and finishing operations.
The learning experience was also a helping tool in making us aware of our role
as garment and textile experts
112