Textile Internship Vardhman
Textile Internship Vardhman
Textile Internship Vardhman
2015
Sagar Sehrawat
Semester V
Department of Fashion Technology
CERTIFICATE
Certified that this project report is the bonafide
work of Sagar Sehrawat who carried out the
project work under my supervision.
MENTOR
SUBMITTED BY:
Mr. Neeraj Jaiswal
Sehrawat
Sagar
Associate Professor
(DFT)
Sem. V
NIFT, Kangra
KGR13AP14
SIGNATURE
SIGNATURE
Acknowledgement
This Internship Proved to bridge the gap between the theoretical and Practical
Aspects of textile Field. It was a great pleasure to be part of Vardhman Group. All
Thanks to my institute NIFT, Kangra for providing me the opportunity for getting the
practical knowledge at such an eminent company.
I am very thankful to the whole Vardhman Group for providing me the best possible
facilities and good environment during the period of my internship. I acknowledge
deep gratitude towards each and every employee of the group for providing me with
their valuable time.
I would like to express my deep gratitude to my mentor Mr. Neeraj Jaiswal for his
patient guidance, enthusiastic encouragement and useful critiques of this research
work.
I would also like to thank my Batch mates and the faculties of NIFT, Kangra for their
views and ideas for the given topic. This proved out to be really helpful for the
Project.
Finally, I wish to thank our CC, Mr. Saurabh Chaturvedi for his support and
encouragement throughout the project.
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 weaving section
Assignment 3:
Observations to be made and information to be documented on the Dyeing section
Assignment 4:
Observations to be made and information to be documented on the different
Departments like Testing, Quality Check, and Management etc.
TABLE OF CONTENTS
1. Group Profile
2. Assignment 1
3. Assignment 2
4. Assignment 3
5. Assignment 4
(Spinning processes)
(Weaving processes)
(Dyeing processes)
(Different Departments with
processes involved)
6. Learning Outcomes
GROUP PROFILE
Acrylic
Fibre
and
Alloy
Steel.
Vardhman Group manufacturing facilities include over 8,00,000 spindles, 65 tons per
day yarn and fibre dyeing, 900 shuttle less looms, 90 million 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:
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 at least 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.
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, and 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 shuttle less
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.
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 5000 crores (about USD 1000 million) in
2013-14. The exports has grown from negligible level in early nineties to Rs 1500
crores (USD 300 million) in 2013-14.
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 , Hand Knitting Yarn
Gassed Mercerised Yarn
Modal Yarn , Speciality Yarn
Tencel Yarn
CUSTOMER FOCUS:
At Vardhman, each customer is special and a constant source of inspiration.
Therefore, the Group has leveraged technology to develop a highly sensitive
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.
for
spiritual
growth
of
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
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.
to
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
to
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.
At Vardhaman ,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 Term
English
Translation
Equivalent 'S'
term
Seiri
Organisation
Sort
Seiton
Tidiness
Systematise
Seiso
Cleaning
Sweep
Seiketsu
Standardisation
Standardise
Shitsuke
Discipline
Self - Discipline
ORGANIZATIONAL STRUCTURE
Chief Managing
Director
MR. S.P. OSWAL
Executive Director
MR. SACHIT JAIN
Vice-President
(Commercial &
Administration)
Chief
Manager
Managers
(Accounts/HR/Costi
ng/Commercial)
Executive,
Officers &
Staff
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
Manager (Dye
House)
MR. ATUL
VERMA
Executive,
Officers & Staff
Executive,
Officers &
Staff
Production
Supervisors
Production
Supervisors
Workmen
Workmen
ASSIGNMENT- 1
24,422 spindles
Production of yarn per day: 16,000 kg
Product Range:
10s-60s
UNIT 2 (HALL 2)
Manufacturing Activity: Sliver preparatory and sample line
Unit Capacity:
1382 spindles
Production of sliver per day: 9,000 kg
Product Range:
UNIT 3 (HALL 3)
Manufacturing Activity: Cotton and lycra (bulk orders)
Unit Capacity:
38592 spindles
Product Range:
UNIT 4 (HALL 4)
Manufacturing Activity: Open- end yarn
Unit Capacity:
1248 rotors
Production of yarn per day: 12,000 kg
Product Range:
6s-20s
UNIT 5 (HALL 5)
Manufacturing Activity: Compact (Elite) spun yarn
Unit Capacity:
14256 spindles
Production of yarn per day: 4000 kg
Product Range:
o 40s-200s
&
Sorting
Mixing
Blowroom
Carding
Pre-Combing
Combing
Draw
Frame
Speed
Ring
Frame
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
Moisturize 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.
J-34
28-29
30-31
5.1-5.2
4.8-5.0
72-76
8-9
S-6
29-30
30-31
5.2-5.3
3.8-4.2
76-80
8-9
39 x 25 x 49
400 kg
44mm
1.2 Dtex
Bright
40 x 24 x 46
300-350 kg
40mm
1.3 Dtex
Bright
GODO
WN NO.
114
67A
105
LENGT
H (in ft)
160
100
100
WIDTH
(in ft.)
85
60
60
AREA
(in
MATERIAL STORAGE
sq.
Ft.)
13600
6000
6000
55
75.2
60
4512
All
Types
of
5
6
7
8
9
1
33
35
105A
66
66A
37
80
75
100
60
43
66
90
80
60
42
50
44
7200
6000
6000
2520
2150
2904
Yarns
Raw Cotton
Raw Cotton
Grey Yarn
Grey Yarn
Grey Yarn
Grey Yarn
63
66
47
3102
Grey Yarn
64
66
47
3102
Grey Yarn
36
152
45
6840
GODOWN
Filament
0
1
2
3
R.
NO.
1
NO.
LENGT
H (in ft.)
WIDT
AREA
MATERIAL STORED
sq.
95
92
Ft.)
8740
Godowns (A)
S.T.-II
95
92
8740
Raw Cotton
Godowns (B)
S.T.-II
95
92
8740
Raw Cotton
Godowns (C)
S.T.-II
59
47.5
2805
Raw Cotton
S.T.-II
Godowns (D)
Raw Cotton
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 lay down 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 lay down which consists of two or
more varieties, in the approximate ratios, according to the end-product requirement.
Machines used:
UNIFLOCK
CONDENSER
MAXI
FLOW
HEAVY
PARTICLE
SEPARATERASTA
MPM
CVT
-3
SECUROMAT
C-4
CARD
DK
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.
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.
Diameter
Colour Code
Function of Pipeline
of Pipes
Location
(mm)
Green
Blue
Material
300
Transportation
Card)
50
3
Yellow
Microdust
300
300
Transportation
4
Red
Fire Diversion
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.
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 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.
Asta: Heavy particles are separated in this machine before they go to MPM4 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 Vardhman,
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
colour contamination sorter (CCS).
Width of the machine: 1600mm
Capacity: 600- 800 kg/hr
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, still exist 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.
CARDING
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 under casing and back plate below and in front of the rollers
respectively. Under casing 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.
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.
Carding Machine
Machine Specifications
Cylinder Speed
Licker-in Speed
Doffer Speed
Flat Speed
Cylinder Diameter
Licker-in Diameter
Doffer Diameter
Can Diameter
Can Height
450-500 rpm
1100-1200 rpm
25-30 rpm
22-25 cm/min
1290 mm
250 mm
500 mm
24
42
Technical Specifications
Linear Density of Lap Fed
Rate of Feed
Length of Sliver/Can
Weight of Sliver/Can
Linear Density of Sliver
Production/min
Production/hour
Production (kg/hr)
400 gm/m
500 gm/min
5500 m
26 kg
4.8 gm/m
85 m/min
5100 m/hr
25 kg/hr
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
Machine specifications:
Linear Density of Sliver Fed
Rate of Feed
Weight of Lap Delivered
Weight of Bobbin
Net Weight of Material
Length of Lap
Linear Density of the Lap
Time taken for one Lap
Delivery Speed
Delivery in gm/min
Production in kg/hr
4.8 gm/m
75-120 gm/min
10.45 kg
1.25 kg
9.2 kg
150 m
61.33 gm/m
150 seconds
60 m/min
3679.8 gm/min
220.74g/hr
Unilap machine
This machine performs the combined function of sliver lap and ribbon lap. Its major
advantage is that it takes less time than the two machines combined.
COMBING
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
Length of Machine
Width of Machine
Loading of Rollers
Can Diameter
Can Height
8
5.169 m
1.318 m
Pneumatically
18
40
Technical Specifications:
Noil Percentage
Feed Lap Weight
Feed Lap Width
Feed Lap Diameter (max)
Delivery Speed
Length of Sliver in One Can
Time Taken for One Can
Output/Machine
Nips/min
Combing Machine
8-25%
62.5 gm/m
300 mm
450 mm
32 m/min
4000 m
125 minutes
16-40kg/hr
300
DRAW FRAME
Manufacturer: Lakshmi
Manufacturer: RIETER
The main objectives are;
Machine Specifications:
LDO/6
Number of Deliveries
Can Changing System
Roller Weighing
Calendar Rollers Weighing
Can Diameter
Can Height
Top Roller Diameter
Calendar Roller Diameter
2
Automatic
Pneumatic
Pneumatic
18
40
38.2 mm
62 mm
RSB 851
Delivery Speed
Rate of Feed
Top Roller Diameter
Can Changing System
Delivered Sliver Weight
250-750 m/min
20-50 gm/min
39.2 mm
Automatic
4.8-4.92 gm/m
parameter
RSB 851
LDO/6
Number of Deliveries
Can Changer
Creel Driving
Delivery Speed (max)
Creel Capacity
Number of Doublings
Single
Automatic
negative
800 m/min
8
8
Double
Automatic
Positive
500 m/min
16
8
2.
3.
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
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 shouldnt 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.
Simplex Machine
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:
C. Undrafted roving:
Reasons:
required count.
Hard bobbin:
Reasons:
D. Soft bobbin:
Reasons:
in calculation of fly and fluff from the surroundings into the roving
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
Machine Specifications:
Number of Spindles
Bobbin Length
Bobbin Diameter
Flyer Speed (max.)
Delivery Speed (max.)
Full Bobbin Weight (max.)
Drafting System
120
32 cm
4.8 cm
1400 rpm
30 m/min
3 kg
3/3
Technical Specifications:
Linear Density of Sliver Fed
Delivery Speed
Length of Roving on one Bobbin
Production/hour/spindle
Production in kg/hour/spindle
Waste Percentage
TPI
4.8 gm/m
18 m/min
2000 m
1080 m/hr
0.772 kg
1%
0.96
RING FRAME
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.
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 Traveler: it is a metallic ring on which the traveler 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.
Ring Frame
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.
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 traveller acc. to the count.
(v)
B. YARN FAULTS:
(i) Double roving:
Mingling of broken roving with the neighboring 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.
(vii)
So, it can break and create more waste and effect the production & quality
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.
Machine Specifications:
Spindle Height
Spindle Diameter at Top
Spindle Diameter at Bottom
Distance Between Two Spindles
Length of Separators
Number of Spindles Per Ring Frame
Spindle Speed (max.)
Delivery Speed
TPI
240 mm
11 mm
15 mm
70 mm
140 mm
448
18000 rpm
18 m/min
21.06/19.58
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
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.
Machine Specifications:
Number of Drums on the Machine
Number of Bobbins on the Creel
Distance Between Two Spindles
Drum Speed
Splicing
Magazine Capacity
60
5
13
1300-1600 m/min
Pneumatic
6
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.
CONDITIONING
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:
Conditioning room for yarn where sprinklers impart moisture before the
cones undergo conditioning in the Xorella Machine.
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
Palette 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.
The carton packing is less cost effective as the cartons are not
reusable
Willowing
Simplex
Machine
Ring
Frame
Removal of unwanted deformities of yarn and converting the ring frame yarn into a
bigger package
Autoconer
Cheese
Winding
TFO
Reeling
Two For One twister where plied yarns are twisted in order to achieve the output.
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.
CARDING
30-35 kg
100% Acrylic,
Blends
65.75
Nylon,
kg/hr
Polyester
and
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.
No. of Faller
Delivery Cans
Can Specification
Diameter of Top Roll
Bottom Delivery Roll Diameter
Drafting Range
Number of Cards fed to the machine
Capacity
2 x 72
1, 2 or 4
800 x 1100 mm
80 mm
60 mm
4.1- 11.9
8
GN type: 800-1000kg/shift
GC type: 2000-3000 kg/shift
SIMPLEX
Simplex Machine
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
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
Drafting Range
Maximum Delivery Speed
Number of Cans Fed
Feed Roll Diameter
Delivery Roll Diameter
Capacity
Maximum Rubbing
Bobbin Length
Tension range between feed roll and
12
9-26
200 m/min
24
40 mm
25 & 50 mm
100-200 kg/spindle/hr
1100 cycles/min
240 mm
0.3% to 7.8%
draft apron
Tension range between rubbing apron
0% to -11%
0% to 6%
rubbing apron
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.
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
Drafting System
Bobbin Length
Spindle Length
Capacity
400
3
220 mm
240 mm
12-15 metric ton/day
AUTOCONER
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.
Machine Specifications:
Manufacturer
Number of Machines
Number of Heads in one Machine
Diameter of Yarn Guide Drum
Width of Splicing Chamber
Package Diameter (maximum)
Capacity
Jehlafhorjt
5
60
95 mm
3.5 mm
326 mm
8.20kg/spindle/shift
TFO
Machine Specifications:
Number of Spindles
Number of Spindles/Section
Spindle Gauge
Pot Diameter
Twist Range
Package Type
Maximum Length of Package (mm)
Spindle Speed
Stop Motion
Machine Width
Machine Length
168
6
254
168 mm
2.5-4.3 TPI
Cheese
170
12000 rpm
Mechanical
1.1 m
23.3 m
CHEESE WINDING
REELING
This is the process which is carried out in order to convert bobbins to hanks
depending upon the customers request. Each machine has 44 heads for preparing
44 hanks. Weight of the hank also depends upon the customers specifications.
Number of Machines: 18
Time taken for winding 44 hanks: 10 minutes for hanks of 150 gm each
PACKING
For worsted spun yarns, packing is done in three ways:
Hank Packing (Automatic packer)
Cone packing (Palette)
Carton Packing
Auto packer
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.
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.
Crochet Machine
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.
Sequins are kept on the top inside a very long inverted tube from
where the sequins are fed into the yarn periodically
ASSIGNMENT- 2
Preparatory unit
4 loom sheds
Folding and inspection unit
Plain, twill, satin, matt, oxford, pique cord weaves are produced on the
looms.
Weft wise stretch fabrics are also produced in Auro weaving mills. In weft
core spun yarns are used in which the core is of Lycra.
Daily production of Auro weaving mills- 70,000 10,000 metres of
Winding
Warping
Warp
Preparation
Yarn from
spinning
section
Sizing
Drafting/
Drawing
Yarn
Preparation
Looming
Weft
Preparation
Winding
Weaving
PREPRATORY UNIT
The preparatory unit has the following sections:
WARPING
The process of arranging a convenient number of warp yarns that can be
collected in a sheet form and wound on to a warpers beam.
The aim of warping is winding on one package to a certain number of
warp-ends of a particular length. During warping, ends from many winding
packages are wound on a common package to prepare a warp beam.
Requirements for warping
MACHINES USED
PROCESS
In one warping machine only 640 threads can be wound on the warpers
beam but the number of threads needed in the fabric is much more than
that. So the number of threads is divided accordingly in a ratio and a
number of warp beams are created.
If warp must have m threads, the total no. of ends as divided by a certain
no. N no. of possibly equal parts containing p ends, which are wound on
a warping beam. Upon warping n beams with p ends on each, a set of
beams with a total no. of ends m=p * n is formed which is necessary for
producing the given fabric.
For example if the number of warp threads required are 10,000. So, 20
warper beams are made each with 500 threads.
Creel
Package
Y
arn
T
ensioners
Y
arn
stop
motion
Sensor
Y
arn
guides
Expanding
Comb
Guide
roller
Warpers
beam
REWINDING
Rewinding is done to utilize the remaining yarn in packages after the
completion of warping beam and to form big packages from small
packages.
No. of rewinding machines: 1
Type: drum type winding
SIZING
The main purpose of sizing is to improve strength and abrasion resistance
of the warp yarns by causing the fibres to adhere together to make
smooth and to lubricate the warp yarns so that there is minimum friction
where they rub together various parts in the weaving process. Sizing
increases the abrasion resistance of the yarn. Softeners are added so the
yarn does not become brittle.
SIZING Chemicals
Starch
Binder
Acrylic base
Softener
MACHINEs
Creel zone
Size box A
Size box B
Pre dryer
Final dryer
Waxing zone
Dry split zone
Comb
Weavers beam
DRAWING-IN
LOOM SHED
Weaving involves using a loom to interlace of two sets of threads at right
angles to each other: the warp and the weft (older woof). One warp thread
is called and an end and one weft thread is a pick, the warp threads are
held taut and in parallel order, typically in a loom of which there are many
different types. Weaving can be summarized as a repetition of these three
actions:
Primary Motions
Secondary Motions
Tertiary Motions
Primary Motions
The frame
The cloth-roll
The reed
MACHINES USED
Vardhman has 4 Loom shed units. All the units have air jet looms. Air jet
looms are shuttle less looms that use compressed air to propel the weft
thread.
Air jet looms are used for bulk weaving. It requires an even yarn and good
quality of sizing. Air jet looms are used to produce basic weaves.
Auro weaving mills have a total of 264 air jet looms.
Count
range:
70
0/e
to
(10,12,14,16,20,30,40,50,60,70,80)(for lycra)
80s
singles,
unit 2
unit 3
88 airjet
looms
48 airjet
looms
unit 3A
48 airjet
looms
Airjet looms
(72+88+48+56)
Tsudakoma
Picanol
Toyota
Tsuakoma 205i
Picanol OMNI
Tsudakoma 209i
Picanol delta-x
Tsudakoma zax
Knotting
Process to join warp of new weaver beam with old warp sheet using
knotting machine.
Gaiting
Gaiting is to replace old weavers beam, drop wires, healdwires, and reed
with new one.
Jet looms take the weft yarn across the loom by using high speed air
blast nozzles.
The drag force of air carries the yarn from one side to the other.
The initial propulsion force is provided by a main nozzle.
Relay nozzles (auxiliary nozzles) along the shed produce additional
booster jets to help carry the yarns across the loom.
The fabric width of air-jet loom is normally narrower than rapier or
projectile loom
Jet looms are faster than projectile or rapier looms (picks per
minute).
However, they cannot produce as great a variety of fabrics (no
heavy or bulky yarns), nor can they produce as a wide a fabric (jets
have less yarn-carrying power).
Jet looms also do less damage to the warp since there is no abrasion
of this yarn by the jet of air, unlike the projectile or rapier.
Safety Measures
Before starting m/c, keep ones hands away from reed & other loom
parts
For drawing yarns manually, use yarn drawer
Keep emergency button pressed if one has to work on loom
Over 9 inch
Holes and openings 1 inch or less
Over 1 inch
4
2
4
Inspection
Folding/Rol
ling
Bale
Sorting
Bale
Packing
MACHINES
Inspection Machines
Machine: almac inspection machine
No. Of machines: 9
ROLLING machines
Machine: laxmi lx450 (for Lycra) and laxmi rolling machine (for 2 ply and
fine fabrics)
No. Of machines: 2
Folding MACHINES
Machine: laxmi folding machine
No. Of machines: 1
Stain
Slub
Contamination
Major defects
Bent pick
Double pick
Thick place
Stain mark
Oily weft
Weft distortion
Stained pick
The defects are marked by tying a thread at the selvage where the defect
has occurred.
Preparatory Unit
In the preparatory unit the warp yarns are prepared for weaving. The
preparatory unit consists of
Warping SECTION
W A R P IN G
WARPING
S E C T IO N
SECTION
D
IR E C T
DIRECT
W
A R P IN G
WARPING
S
E C T IO N A L
SECTIONAL
W
A R P IN G
WARPING
Direct warping
It is used for long runs of grey yarns, single colour yarns and simple
patterns of coloured yarns. It can be used to make warp sheets. The total
amount of coloured yarns involved is less than 15% of the total.
Suction devices are provided in between warping machines which suck all
the unwanted cotton fibres flying.
MACHINES
Temperature range:
Relative humidity:
27-30c
60-80%
Rewinding Section
Rewinding is done to utilize the remaining yarn in packages after the
completion of warping beam and to form big packages from small
packages for selling purpose.
MACHINE
Sizing section
S
IZ IN G
SIZING
S
E C T IO N
SECTION
S
I Z IN G
SIZING
K
IT C H E N
KITCHEN
S
I Z IN G
SIZING
M
A C H IN E
MACHINE
Sizing KITCHEN
Size is prepared at the top floor in the sizing kitchen and transferred to the
machine with the help pipes.
Sizing APPARTUS
PRESSURE
COOKER
PREMIXER
STORAGE VESSEL
SIZING ingredients
Texoplast
Sonycryl
Mutton tallow
Water
Ketanol
Antistatic
Sizing MACHINE
No. OF MACHINEs: 3
Tsudakoma: Only For Direct Beam
Moenus Sucker: Both For Direct & Sectional Beam
Moenus Sucker: Only For Sectional Beam.
DRAWING-in SECTION
DRAWING-IN DEPARTMENT
MANUAL DRAWING-IN
AUTOMATIC DRAWNGIN
WASHING &
CLEANING SECTION
Manual Drawing-in: Done manually to draw warp yarn through drop pins,
heald frames, and reed. Two workmen:
Loom shed
Total loom : 224
Airjet looms : 142
Rapier looms : 82
AIRJET LOOMS
(24+118)
RAPIER LOOMS
(6+74+2)
TSUDAKOMA ZAX
PICANOL GTX
TSUDAKOMA
ZAX9100
PICANOL GAMMAX
DORNIER GPX
Knotting
It is the process to join warp of new weaver beam with old warp sheet
using knotting machine.
Gaiting
Gaiting is to replace old weavers beam, drop wires, healdwires, and reed
with new one.
Inspection zone.
Bale sorting zone.
Bale packing zone.
Machines
Inspection machine
No. of machines: 7
Manufacturer: Laxmi
Mending table
No. of machines: 2
Manufacturer: Laxmi
Folding MACHINE
No. of machines: 2
Manufacturer: Laxmi
Rolling Machine
No. of machines: 1
Manufacturer: Laxmi
No. of machines: 1
Manufacturer: Navjyot machine works ltd
No. of machines: 1
Manufacturer: Laxmi
DESIGN DEVELOPMENT
PROCESS
Research
Selection of raw material
Process control
Process development
Product testing
Quality assurances
Specification tests
AURO TEXTILES
VARDHMAN Groups has stepped into the textile industry with the setup of
AURO Textiles at Baddi (H.P). Chief Minister of Himachal Pradesh, Mr. Prem
Kumar Dhumal inaugurated it and its production started in December
2000.
The whole plant covers an area of 12 acres of land. Since Textile field is
new to this group so they had their technical collaboration with the
renowned group of Japan TOKAI SENKO. All the machinery installed in
plant was imported from Japan, Italy & Germany. At present the plant has
the capacity to produce 30 lakh Meter/ Month of fabric.
The plant is self-sufficient in prospect of the following:
The plant not only uses the above utilities (power and steam) for its own
consumption but also supply to its sister concerns also as: Power
Steam
Auro dyeing
VSGM 100 % Export oriented unit
Auro Weaving mills
Greige fabric or piece dyed fabric comes from both Auro spinning mills
and Mahavir spinning mills. Yarn dyed fabric comes only from Mahavir
spinning mills.
Preparatory section
Dyeing section
Finishing section
Inspection and folding
Technical section
Preparatory section
The Fabric from the mills is received in the following Forms:
Roll Form
Bale form
Pallet form
Firstly the grey cloth is send to technical department where the physical
and chemical testing of grey cloth takes place. After testing of cloth, all
the reason is written in the dispo sheet by technical department and a
copy of all is send to all the concerned departments and now it is ready
for grey checking which is examined on grey checking machine.
Then fabric ends are stitched so that a fabric batch of longer length is
formed. This facilitates that processing can be carried out continuously.
The fabric ends are stitched together with help of stitching machines.
The fabric received by Auro textiles contains many natural and chemical
impurities which have to be removed to increase the dye affinity of the
fabric and to add value to the fabric.
PRE-TREATMENT
The pre-treatment of fabric is done to remove impurities, add value to the
fabric and enhance its appeal.
SINGEIN
G
DESIZIN
G
SCOURI
NG
BLEACHI
NG
WASHIN
G
DRYING
Singeing
Singeing is the burning off of loose fibres sticking out of textile goods. It is
usually the first step carried out after weaving. Singeing is done through a
flame produced by propane and air.
Purpose
Reduce pilling
Increased wet ability.
Improved visibility of the fabric structure
Decreased contamination through removal of fluff and lint.
MACHINES
No. of machines: 2
Machine 1:
Machine 2:
FABRIC QUALITY
SPEED (m/min)
Bottom weight
60 70
2.
90 100
3
4
For 2 ply
Yarn dyed
50-70
120
TYPES OF DESIZING
Process
The fabric is first washed with hot water in washer 1 to washer 4. The
temperature is 90 degree Celsius. Due to the hot water wash 30-40% size
is removed. Then a cold wash is given to the fabric in washer 5. Then the
fabric goes to the desizing scouring saturator where it is padded with
chemicals and then sent to the reaction chamber- a where it is allowed to
stay for some time so that the chemicals react with the fabric. The
scouring and desizing chemicals are added in the same chamber.
Chemicals used in DESIZING scouring SATURATOR
Machines
FABRIC TYPE
100% Cotton (B/W)
100% Cotton 30 s
100% Cotton (SHIRTING)
2 PLY Fabric
Polyester /Cotton
Bleaching
Bleaching is the process of removing natural pigments and vegetable
impurities. Oxidative bleaching is done with help of hydrogen peroxide
and sodium hypochlorite.
For yarn dyed fabrics, fabrics dyed using reactive dyes are not bleached while
fabrics dyed with vat dyes are bleached.
Purpose
Improved whiteness
Level dyeing properties
Process
After the reaction chamber-A the fabric is washed in hot water in washer 1
to washer 4. Then the fabric is given a cold wash in washer 5 to bring the
fabric to room temperature. Then the fabric goes to peroxide bleaching
saturator where it is padded with bleaching chemicals. Then the fabric
goes to reaction chamber-B where it is kept for some time so that reaction
takes place.
Chemicals used in THE PEROXIDE Bleaching saturator
MACHINEs
CHLORITE BLEACHING:
This type of bleaching is carried out in Old Perble Range not in NEW Perble
Range i.e. this section is not present in NEW PERBLE RANGE. Aim of
chlorine bleaching is to decolourise the natural colouring matter present in
the textile material to leave the fabric in more absorbent state than that
of grey. When the goods are passed from only NaClO 2 solution it is called
half bleach, which are usually to be sent for dyeing of darker shades.
After washing range the fabric passes from saturator and then to reaction
chamber of B range for NaClO 2 bleaching, where dwell time for bleaching
is given. This is basically done due to the formation of highly toxic chlorine
dioxide gas. It involves padding the fabric through the saturator
maintained at room temperature containing bleaching chemicals. And
then passing it onto the Reaction chamber where a hold is given
depending upon the type of fabric, so that the, proper swelling of fiber can
occur and thereby causing proper penetration of chemicals.
Sodium chlorite concentrations are given below
S.No
FABRIC TYPE
.
1
2
3
20 to 22
16
14
Washing
The fabric after passing through the pull out section of the reaction
chamber enters the four washers for effective washing. Temperature of
the washers is kept at 85 degree Celsius. The counter current flow of
water is used in all these washers so as to have a thorough washing of the
fabric.
After each washer there are nipping mangle, nip pressure of each washer
is kept to 2 ton. In order to avoid formation of creases the washers are
provided with an expander roll at their respective exits. After every
washer is a dancer roll so as to maintain the adequate tension in the
fabric. After four washers there is a Plaitor.
This arrangement is in OLD PERBLE not in NEW PERBLE. This Plaitor is
used only when there is no further processing like bleaching, for example
fabrics containing Lycra are not chlorite bleached, so these are plaited at
this very stage. For 100% cotton and P/C blends this Plaitor is by-passed.
The fabric then passes through the cold washer so as to lower the
temperature to room conditions before entering the chlorite saturator.
DRYING
There are three VDRs to dry the fabric. Each of which consists of 10
drying cylinders, the last one consists of 7 drying cylinders and 3 cooling
cylinders, at the end, so as to cool the dried fabric before the Plaitor plaits
it on the trolley. The fabric after washing is passed through nip bowls
having a pressure of 5 tons. Then it passes through the first drying range.
The drying cylinders are steam heated. The main steam pipe is having a
pressure of 6 kg/cm2 and so far each drying range there is a pressure of 2
kg/cm2. Each drying cylinder is provided with two steam lines. One is for
heating the cylinders and other for removing exhaust steam. Cooling
cylinders are cooled with cold water.
Mercerization
Mercerization is a treatment for cotton fabric and thread mostly employed
to give cotton a lustrous appearance. Sodium hydroxide (caustic soda
240gppl) is the chemical used in Mercerization.
Purpose
Improve
Improve
Improve
Improve
Improve
Improve
MACHINEs
No. of machines: 2
Machine: sando iron mercerization range (JAPAN)
PROCESS
The fabric after the pre-treatment is sent for mercerization. The fabric is
first padded with caustic soda in caustic saturator 1 then the fabric goes
to the timing cylinder where some time is given to the fabric to react with
NaOH. Then the fabric is again padded with caustic soda in caustic
saturator 2. Then again fabric goes to the timing cylinder. After this the
fabric is stretched in the feed mangle. Then the fabric goes to the tenter
chain where the fabric is stretched weft wise to maintain its equal width in
the fabric. Then the fabric passes through 5 water showers where the
caustic soda is washed off. Then the fabric is washed in a series of 9
washers. Washer 8 gives a neutralization bath to the fabric and washer 9
gives a cold wash to the fabric. Then the fabric is dries in the vertical
drying range.
TIMING
CYLINDER
CAUSTIC
SA
TURATOR
TIMING
CYLINDER
FEED
MANGLE
TENTER
CHAIN
WATER
SHOWERS
(5)
WASHER
1WASHER
7
(HOT
WASH)
WASHER
8
(NEUT
ALIZA
TIO
N)
WASHER
9
(COLD
WASH)
VERICAL
DRYING
RANGE
STITCHI
NG
PADDIN
G WITH
WATER
DRYING
PASSIN
G OVER
EMERY
ROLLER
S
PASSIN
G OVER
BRUSH
ROLLER
PLAITER
ASSIGNMENT- 3
YARN DYEING
At VARDHMAN, Yarn dyeing is carried out. Mostly hank dyeing is done.
After soft packages of yarn are made the packages are loaded onto long
cylindrical rods which are mounted on the carrier. These rods have small
pores in it which allows movement of dyeing chemicals in and out during
dyeing process.
Yarn dyeing can also be done in beam form, i.e. instead of a cheese;
beams of yarns are loaded in the carrier and dyed. The beams of yarn
come from Mahavir spinning mills and are dyed as it is and sent back for
weaving process.
The cheeses have to be fixed firmly in the carrier so that the packages are
not loosed during dyeing which causes uneven dyeing.
After the dyeing process about 5 grams of yarn is sent for quality check, to
check whether the achieved shade is according to the customers demand
or not.
If not approved the dye recipe is corrected in the SPDM section (single
package dyeing machine) and the dyeing process for the bulk is again
carried out.
If approved then the cheeses are either dried in the rapid dryer or sent
further to RF dryer for drying.
The beams are dried on the rapid dryer. The whole carrier is fitted into the
dryer and the yarns are dried by means of heat.
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.
180 kg
5
2.25 to 3 kg
0.5 kg/cm
Not more than 0.8 kg
98C
2
5 kg/cm
102C
Kier
Sampling devices
Loader
Additional tank
Cooling water outlet
Steam trap
Additional tank drain
Feed pump
Additional flow control
Impeller
Water drain
Pulley
Water supply
Cooling water inlet direct heating
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.
Hydro Extractor
Machine Specifications:
Capacity
RPM of Motor
Cage Drum
Quantity Loaded per Batch
Cycle Time of One Batch
Standard Productivity
DRYER:
Machine Specifications:
Features
Number of Hangers
Temperature
Capacity
Old Dryer
180
95-105C
1 kg
New Dryer
210
95-105C
2.75 g
PRINTING MACHINE:
Manufacturer: 5WA (Italy)
Number of Machines: 1
Number of Colour Tanks: 4
This is a new addition to the VARDHMAN 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.
In this machine, 48 cones are printed at a time. There are mainly 3 rollers:
Furnishing Roller: always remains dipped in color and transfers color to the
other roller.
Engraved Roller: Transfers color to the yarn band and doctor blade here,
removes extra color.
Pressure Roller: provides pressure to the yarn band. Yarns are dried and
hanks are formed.
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.
DYEING
Dressing is done by one of the workers in Hank to Cone section
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
Take 85C warm water & water bulking for 10
minutes
Overflow it at 50C
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 60C at 1C/minute
add the other half colour and dozing it for 10 minutes
Run it for 10 minutes
Raise the temperature at 80C at 11
C/minute
Run it for 10 minutes
Raise the temperature at 90C at 0.5C/minute
Run it for 10 minutes
Raise the temperature at 99C at 0.3C/minute
Run it for 10 minutes
Hold the material and overflow it
Drain the material
Overflow at 40C
Entry of Dyed
Material
in
Hank to
Run it for
10 minutes
Cone Section
Raise the temperature at 99C at 1C/minute
Dressing
Overflow at 40C
Loaded on Winding
Machines
Then add 1% wacker finish & 0.5% Formic Acid
Run it for 10 minutes
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:
Number of Drums on Each Machine
36 (7 machines), 40 (2 machines)
Drum rpm
Weight of Cone
300
1 kg
SSM
Number of Machines: 3
Number of Drums in Each Machine
Drum rpm
Weight of Cone
24
400
2kg
FADIS
Number of Machines: 10
Number of Drums in Each Machine
Drum rpm
Weight of Cone
35
350
2.25
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
customers demand. It gives finishing to the yarn that results in:
Bulkiness
Increase in luster
Improved quality
Attractive look
Soft handle
PACKING:
Packing in VARDHMAN is done in four forms depending upon the customers
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.
Balls are being made in the Automatic Ball Machine; Lea Packing
Bundle Packing
AURO DYEING
Auro dyeing is a part of Auro textiles. In Auro dyeing mainly fibres are
dyed. Fibre is dyed to make melange fabrics and yarns are dyed for yarn
dyed fabrics. Yarns for yarn dyed fabrics made in Mahavir spinning mills
are dyed in Auro dyeing.
Auro dyeing dyes a variety of materials like 100% cotton, 100% polyester,
100% viscose and blends like polyester cotton, polyester-viscose, wool
blends acrylic blends.
The daily production capacity of Auro dyeing is 28 tonnes per day
Fibre DYEING
Machines
PROCESS
The fibre is received by Auro dyeing in form of bales. The fibres are
cleaned and free from impurities. The bales are opened and the fibres are
fed into the carrier with help of feed lattice panel.
After loading the fibres are pressed into the carrier using pressure and
weight.
Dye is prepared in the dyeing machine in the dissolving tank using the
dye recipe already approved by the R & D department. The temperature
of the dye is maintained with help of heating coils in the dissolving tank.
After the fibre is dyed about 5 grams of dyed sample is sent for quality
checking, if the shade achieved is correct then rest of the processing is
carried on. If not some corrections are made in the dye recipe and the
fibres are dyed again.
After dyeing the water from the fibres is extracted using a hydro extractor
and a cake is formed. The carrier is then emptied and the cake is placed
on the cake stand.
After this the rest of the processing is done. First the cake of fibres is
broken in a cake breaker, i.e. the fibres are separated.
Then the fibres pass through a series of tanks where washing is done so
that the extra dye is stripped off. The first tank contains soap solution. In
the second tank a hot wash is given. In the next tank a cold wash is given
to bring the fibres to room temperature. In the last tank softening of the
fibres is done.
After that the fibres are forwarded to the hopper 2 where the fibres are
slightly dried before hydro extraction.
Then water is extracted using hydro extractor. Then again fibres are sent
to hopper 3 where the fibres are separated from each other. Then tumble
dry is done.
After tumble drying sorting of fibres is done, i.e. any fibres of different
shade are taken out.
Then the fibres are pressed and packed in a bale form. The bale contains
information like bale number, lot number, shade, size, weight etc.
END use
The dyed fibres are used to create melange fabrics. They are sent to
arihant spinning mills Ludhiana which is a part of Vardhman.
AND
AND
PRESSING
PRESSING
PREP
PREPARA
ARATION
TION OF
OF
THE
THE T
TANK
ANK
D
DYE
YE
IN
IN
D
YEING
DYEING
QUALITY
QUALITY
CHECK
CHECK
IF
OK, HYDRO
IF OK,
HYDRO
EXTRACTION
EXTRACTION
EMPTYING
EMPTYING
CAKE
CAKE
CAKE
CAKE
OF
OF
CARRIER
CARRIER
FORMED
FORMED
BREAKER
BREAKER
W
ASHING
WASHING
RANGE(
RANGE( SOAPING,
SOAPING, HOT
HOT
W
COLD W
WASH,
ASH, COLD
WASH,
ASH,
SOFTNER)
SOFTNER)
HOPPER
HOPPER
HYDRO
HYDRO
2
2
EXTRACTOR
EXTRACTOR
HOPPER
HOPPER
TUMBLE
TUMBLE
3
3
DR
DRYER
YER
SOR
SORTING
TING
P
PACKING(BALE
ACKING(BALE
FORM)
FORM)
Colour store
The colour store has all the dyes used in the dyeing of fibres and yarns.
The dye recipe is prepared in the colour store for bulk dyeing. When an
order is placed the R & D department prepares a colour recipe according
to the colours available in the colour store. After the recipe is tested it is
converted for bulk dyeing. The recipe is given to the colour store where it
is prepared and given to the dyeing section.
SOME DYE Companies
Jakazol
Hunstman
Dystar
Atul ltd.
Chemical store
For preparing the dye recipe and washing procedures chemicals are
required which are kept in the chemical store and supplied from there. The
chemicals store contains wetting agents, softeners, chelating agents etc.
OBBDM Section
OBBDM is the open box beaker dying machine. When an order is placed 3
samples of a shade are prepared in OBBDM machines and given to the
customer. If the customer approves one of the sample and then the order
proceeds.
QUALITY ASSURANCE
The quality assurance department checks the quality of the incoming as
well the outgoing material. The quality control department checks the
greige yarn, its strength, dye affinity, colour uptake. They check that the
shade of the dyed products match the standard provided by the customer.
They check the colour fastness of the dye and perform various tests on
ASSIGNMENT- 4
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
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
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
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 colour 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
Varieties
Shankar 6
52-54
J-34
46
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
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 details which are fed are the quality of the bales i.e. the variety, number
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.
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
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.
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.
ENGINEERING DEPARTMENT
The 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.
of industrial
relations department,
i.e. manpower
planning,
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 centres 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.
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
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 detentions (detention report) or
stoppages during production. By checking the detention 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.
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.
LEARNING OUTCOME
The learning at Vardhman 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:
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