Chapter - 1

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CHAPTER – 1
INTRODUCTION TO THE STUDY
1.1 ABOUT THE STUDY
The study was conducted in order to find out the Effectiveness in productivity due to the
Modernization programme implemented in Athiswar Textile Mills., The study reveals the
various advantages and importance for a spinning mill to be modernized. A comparative study is
done on the data’s obtained before and after the modernization process.
This report would stand as one of the powerful input for the company to find out whether
the modernization programme have resulted in the overall effectiveness of the organization i.e.,
especially at operational level. Due to the result of this study the company can take necessary
steps in order to increase the productivity, earn profit and achieve their objectives by
implementing similar modernization programmes to other older machines.
The textile industry is growing rapidly with stiff competition and for a company to
survive in a tight market share modernization programmes are mandatory. Therefore, this project
analysis the post and pre modernization process and thus provides valuable inputs on the need
for upgrading the older machines.
1.1.A INTRODUCTION TO MODERNIZATION PROGRAMME
Modernization is interpreted in the restricted sense of replacement of the old machines

with the new ones. We consider both replacement and renovation as modernization as long as
these changes result in improved technology with gains in quality, productivity and cost.
The term modernization is defined as the replacement of entire machines of earlier (or
obsolete) engineering design or technological principle by new and updated machine.
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Planned machinery modernization is of vital importance. For one thing, neglect of modernization
will result in machinery developing operating inferiority, with the inevitable drop in production
rates, as well as quality. Also, the changing scenario of textile markets, with constantly mounting
costs, increasing competition, more and more discriminating consumers and the constant need
for diversification of products to meet ever changing fashions, have all made management of
textile mills realize that they will have to either modernize or close down ultimately.
The profitability of a spinning mill is determined to a large extent on its ability for
reducing ‘real cost’ of production which can be done only through modernization and higher
labour and higher labour and machine productivity. In fact, the root cause of poor working, low
profits and sickness of a mill can be invariably traced to the neglect of modernization over a
period of years. The amount a mill should spend on modernization would, of course, depend on a
number of factors, such as, the level of modernization of the mill, the profitability and now
technology level.
In almost all the mills which have become sick, the amount spent on modernization was
only a small fraction of the norm. In many sick mills as pointed out in the section on fixed assets,
no modernization was carried out for a number of years.
Machines will develop on operating inferiority due to the greater wera and rear of the key
components, and this will reduce the production per spindle at not less than 2% a year leading to
an 8% drop in production.
Further, the machinery breakdowns will also be more frequent resulting in low
utilization. Moreover the quality of yarn will deteriorate, energy costs escalated incidence of
hand waste will be higher and consumption of stores will increase.
Thus, lack of modernization has led to a steep fall in labour and machine productivity.
Besides, the yarn quality is adversely affected and energy cost per unit production is increased
due to the poor condition of machinery in mills. All these have led to huge losses and sickness of
the units.
How much a mill should spent on machinery modernization. This would, of course,
depend on a number of factors such as the current level of modernization of the mill, the
profitability, new technological developments and above all the availability of new machines. As
a broad guideline, the annual investment on modernization should be about 3 to 4% of the sales
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revenue and the mills should ensure that they get a return of not less than 25% of their
investment.
1.1 ABOUT THE INDUSTRY
India is a traditional textile -producing country with textiles in general, and cotton in
particular, being major industries for the country. India is among the world’s top producers of
yarns and fabrics, and the export quality of its products is ever increasing.
Textile Industry is one of the largest and oldest industries in India. Textile Industry in
India is a self-reliant and independent industry and has great diversification and versatility. The
textile industry can be broadly classified into two categories, the organized mill sector and the
unorganized decentralized sector. The organized sector of the textile industry represents the
mills. It could be a spinning mill or a composite mill. Composite mill is one where the spinning,
weaving and processing facilities are carried out under one roof. The decentralized sector is
engaged mainly in the weaving activity, which makes it heavily dependent on the organized
sector for their yarn requirements. This decentralized sector is comprised of the three major
segments viz., power loom, handloom and hosiery. In addition to the above, there are readymade
garments, khadi as well as carpet manufacturing units in the decentralized sector.
The Indian Textile Industry has an overwhelming presence in the economic life of the
country. It is the second largest textile industry in the world after China. Apart from providing
one of the basic necessities of life i.e. cloth, the textile industry contributes about 14% to the
country's industrial output and about 17% to export earnings. After agriculture this industry
provides employment to maximum number of people in India employing 35 million people.
Besides, another 50 million people are engaged in allied activities. India is the largest producer
of Jute, the 2nd largest producer of Silk, the 3 rd largest producer of Cotton and Cellulosic Fibre /
Yarn and 5th largest producer of Synthetic Fibers/Yarn. Textile Industry contributes around 4%
of GDP, 9% of excise collections, 18% of employment in industrial sector, and has 16 % share in
the country’s export. The Industry contributes around 25% share in the world trade of cotton
yarn. India is the largest exporter of yarn in the international market and has a share of 25% in
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world cotton yarn export market. India contributes for 12% of the world’s production of textile
fibers and yarn. Indian textile industry is second largest after China, in terms of spindleage, and
has share of 23% of the world’s spindle capacity. India has around 6% of global rotor capacity.
The country has the highest loom capacity, including handlooms, and has a share of 61% in
world loomage. The Apparel Industry is one of largest foreign revenue contributor and holds
12% of the country’s total export.
Strengths of the Textile Industry:
The following are few strengths of the Indian Textile Industry:

 An Independent and self-reliant industry;
 Large and potential domestic and international market;
 Abundant Raw Material availability that helps industry to control costs and reduces the
lead-time across the operation;
 Availability of low cost and skilled manpower provides competitive advantage to
industry;
 Availability of large varieties of cotton fiber and has a fast growing synthetic fiber
industry;
 Promising export potential.
Weaknesses of the Textile Industry:
The following are the few drawbacks of the textile industry, which it has to overcome.
 The Industry is a highly fragmented Industry.
 It is highly dependent on Cotton.
 There is lower productivity in various segments.
 There is a declining in Mill Segment.
 Lack of Technological Development that affect the productivity and other activities in
whole value chain.
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 Infrastructural Bottlenecks and Efficiency such as, Transaction Time at Ports and
transportation Time.
 Unfavorable labor Laws.
 Lack of Trade Membership, which restrict to tap other potential market.
Market Size:
A leading sector in the Indian economy, textiles contributes 14 per cent to industrial
production, 4 per cent to the GDP and around 17 per cent to the total export earnings. It is, in
fact, the largest foreign exchange earning sector in the country. India is the world's 2nd largest
cotton producing country, after China. BT cotton was a major factor contributing to higher rate
of production, from 15.8 million bales in 2001-02 to 31 million bales in 2007-08. India accounts
for:
 61 per cent of the global loom age
 22 per cent of the global spindle age
 12 per cent of the world's production of textile fibres and yarn.
 25 per cent share in the total world trade of cotton yarn.
The textile industry size has expanded from US$ 37 billion in 2004-05 to US$ 49 billion in
2006-07, the domestic market increased from US$ 23 billion to US$ 30 billion, and exports
increased from around US$ 14 billion to US$ 19 billion. India's textiles and apparels industry is
estimated to be worth US$49 billion where 39 per cent is accounted by the exports market. The
total exports in 2006-07 were US$ 19.62 billion. Currently India has a 3.5-4 per cent share in
world export of textiles and 3 per cent in clothing exports. The cloth production during 2006-07
was 53,389 mn. sq. mtr. The sectorwise compound annual growth rate during the last five years
works out to 6.20%. The non-woven and technical textile produced by India is approximately
US$ 8 billion, which amounts to six to eight per cent of world production. The handloom sector,
which is the second largest sector in terms of employment accounts for about 13% of the total
cloth, produced in the country (excluding wool, silk and Khadi).
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1.2 ABOUT THE COMPANY
Company profile
ATHISWAR TEXTILE MILL manufactures several kind of cotton yarns in cone, in

technical specification it is termed to as counts which is unit of yarn specified by the textile
industries. The yarn produced here meets the necessity of the local sizing units and as well high
quality yarn travel all over India through buyers.
It was established in the year 2003 with a capital of 7 crore. The managing director of the
concern is Mr. M.Palanisamy; he obtained his M.B.A degree under Anna University, Chennai in
the stream of Finance which urged him to become a Entrepreneur. The main aim of him to start
the industry is to establish a major industry where the competition is less and of course which
offers him a high profit being a monopoly in the local market.
The profit of the concern is on increasing trend due to vibrant management policies
followed by the higher authorities. Although there are a number of concerns which struggled
from down trend it is the up gradation process which helped the concern grow. At present the
concern has two child plants namely Sri Soliswara spinners in Thudiyalur and Jai Vigneshwar
Spin tech in K.Ayyampalayam.
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A brief profile of the company is given below:
Name of the Company : ATHISWAR TEXTILE MILL
Year of Establishment : 2003
Address of the company : K.Ayyampalayam,
Palladam(post), Coimbatore-641662.
Installed capacity : 11400 spindles
Nature of the Business : Manufacturing of cotton Yarn in cone
Type of Industry : Textile
Location : K.Ayyampalayam,Palladam
Paid up capital : Rs.4 Crores
Loan from Bank : Rs.1Crores
Product : Yarn
Quality : 40’s, 30’s
Number of workers : 300

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Organizational Structure
MANAGING DIRECTOR
FACTORY OFFICIER ADMINISTRATIVE OFFICIER
SPINNING MASTER POWER HOUSE
ELECTRICAL
SHIFT SUPERVISORS SUPERVISORS
MASTRIES SHIFT SUPERVISORS
LABOURERS
ESI/PF CLERK HEAD TIME KEEPER CASHIER STORE KEEPER COTTON/YARN CLERK
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SHIFT CLERKS OFFICE ASSISTANT
Product Profile
With its strict operating principles the company manufactures yarns of the following
specification as ordered by the buyer/sizing units.
 40’s count
 30’s count
 20’s count
 10’s count
COUNT = Thickness of the Yarn Produced from cotton

Count >> = Yarn Thickness <<
Manufacturing Facility
With the turnover of around 5 to 10 Million every year, we have equipped with the latest
technology, machineries and devices. We are completely dependent and capable of producing
30000Kgs every month, (approximately 600bags).
1 Bag = 40 Cons
1Con = 1.3 Kgs
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Process Flow
BLOWROOM
CARDING
DRAWING
SIMPLEX
SPINNING
WINDING
PACKAGING
The spin plan or the counts to be manufactured will be decided well in advance according to
the market demand or the demands of the customer. Again it depends upon the raw material
availability and balancing of the process in each department.
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 Job production
 Mass production
 Small batch production
GINNING
A cotton gin (short for cotton engine) is a machine that quickly and easily separates the
cotton fibers from the seeds, a job previously done by hand. These seeds are then used to grow
more cotton, produce cottonseed oil, or, if badly damaged, are disposed of. It uses a combination
of a wire screen and small wire hooks to pull the cotton through the screen, while brushes
continuously remove the loose cotton lint to prevent jams.
The ginned cotton fibre, known as lint, is then compressed into bales which are about
1.5m tall and weigh almost 220 kg. Only 33% of the crop is usable lint. Commercial cotton is
priced by quality, and that broadly relates to the average length of the staple, and the variety of
the plant. Longer staple cotton (2 1/2 in to 1 1/4 in) is called Egyptian, medium staple (1 1/4 in to
3/4 in) is called American upland and short staple (less than 3/4 in) is called Indian.
BLOW ROOM
Blow room installations consists of a sequence of different machines to carry out

the above said operations.Moreover Since the tuft size of cotton becomes smaller and
smaller, the required intensities of processing necessitates different machine configuration.
Basic operations in Blowroom :

 Opening
 Cleaning
 Mixing/Blending
 Microdust removal
 Uniform feed to the carding machine
 Recycling the waste
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 Opening in blowroom means opening into small flocks.Technological operation of

opening means the volume of the flock is increased while the number of fibres
remains constant. i.e. the specific density of the material is reduced.
 The larger the dirt particle , the better they can be removed
Since almost every blow room machine can shatter particles, as far as possible a lot
of impurities should be eliminated at the start of the process. Opening should be
followed immediately by cleaning, if possible in the same machine.
 The higher the degree of opening, the higher the degree of cleaning. A very high
cleaning effect is almost always purchased at the cost of a high fibre loss. Higher
roller speeds give a better cleaning effect but also more stress on the fibre.
 Cleaning is made more difficult if the impurities of dirty cotton are distributed
through a larger quantity of material by mixing with clean cotton.
The raw cotton arrives in the form of large bales. These are broken open and a worker
feeds the cotton into a machine called a "breaker" which gets rid of some of the dirt. The
cotton may not be consistent in quality from bale to bale and samples will be taken. This
machine cleans the cotton of the remaining dirt and separates the fibres. The cotton
emerges in the form of thin "blanket" called the "lap". An important quantity is called the
"tex" which basically measures the mass per metre. Ideally the tex of the emerging lap
should stay more or less the same. The final end product of the mill, the yarn, needs to be
of constant quality and character and this is achieved by checking the cotton through all the
preceding stages.
Tex is the weight in grams of 1 km of yarn
CARDING
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"Card is the heart of the spinning mill" and "Well carded is half spun" are two
proverbs of the experts.These proverbs inform the immense significance of carding in the
spinning process.
High production in carding to economize the process leads to reduction in yarn

quality. Higher the production, the more sensitive becomes the carding operation and the
greater danger of a negative influence on quality.The technological changes that has taken
place in the process of carding is remarkable.
Latest machines achieve the production rate of 60 - 100 kgs / hr, which used to be 5
- 10 kgs / hr, upto 1970.
Purpose of Carding:
 to open the flocks into individual fibres

 cleaning or elimination of impurities
 reduction of neps
 elimination of dust
 elimination of short fibres
 fibre blending
 fibre orientation or alignment
 sliver formation
The two main ways to card fibers are by
 Hand
 Machine
 HAND CARDING
To card by hand, the person carding holds a carder in each hand. The carder in
their non-dominant hand rests on their leg. They place a small amount of fiber on this card
and pull the other carder through, while taking care to catch some of the fibers. By
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catching some fibers on the moving card, the fibers are separated, which allows vegetable
matter to fall out, and they are aligned. Once all the wool has been transferred, the person
carding repeats this process until all the fibers are aligned and the fiber is satisfactorily
clean of debris. They then roll up their carded wool into a neat role.
 MACHINE CARDING
Machine carding is done on a device called a drum carder. These devices vary
in size from small to large. Depending on the size of the carder, the number of rollers
varies. In Kitchen type carders, they have two drums, or rollers. One is small, and used to
catch the fibers and feed them in. The other drum takes the fibers from the first drum, and,
in the process of transferring them from one drum to another, the fibers are straightened
out and made more orderly.
In Carding the fibres are separated and then assembled into a loose strand called
sliver or tow. The carders line up the fibres nicely to make them easier to spin. The cotton
leaves the carding machine in the form of a sliver; a large rope of fibres.
There are two types of feeding to the cards

1. Feeding material in the form of scutcher lap
2. Flock feed system (flocks are transported pneumatically)
SIMPLEX
In this process the output of drawing is drafted, twisted to make roving bobbin form.In
simplex section, sliver is fed and roving is produced. Finisher sliver is drafted and very low twist
is inserted to form Roving. Roving is final preparatory shape of yarn in Back process stage,
which will be converted into yarn in ring department.
SPINNING
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The spinning machines take the roving thins it and twists it, creating yarn which it
winds onto a bobbin. The term "spinning" is sometimes used to denote this final process in
the production of the yarn. This involves attenuating (stretching) the yarn to the required
tex. There by giving the thread strength by adding twist and winding it on to a bobbin.
There are two main methods
 Mule spinning
 Ring spinning
MULE SPINNING
The MULE was originally developed by Samuel Crompton from the "jenny". In
mule spinning the roving is pulled off a bobbin and fed through some rollers, which are
feeding at several different speeds. This thins the roving at a consistent rate. If the roving
was not a consistent size, then this step could cause a break in the yarn, or could jam the
machine. The yarn is twisted through the spinning of the bobbin as the carriage moves out,
and is rolled onto a cop as the carriage returns. Mule spinning produces a finer thread than
the less skilled ring spinning. The mule operated in two stages. In one stage the whole
'front' of the machine is moved away from the back part stretching and twisting the thread
as it did so. It would move several feet (say 5 feet). In stage two the front carriage moved
back and at the same time wound the stretched yarn on to a bobbin (or cop).
Mules would be placed in lines so that the front of one faced the front of the next.
As the carriages moved forward, towards each other, only a narrow gap would be left
between them for the spinner to walk between. The mules were tended by spinners,
piercers, doffers.
 Piercers would mend broken threads and

 doffers would remove the full cops
Doffing is a separate process. The attendant winds down the ring rails to the
bottom. The machine stops. The thread guides are hinged up. Removing the bobbin coils
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thread around the spindle, and placing the new bobbin on the spindle firmly traps the
thread between it and the cup in the wharf of the spindle. This done, the thread guides are
lowered and the machine restarted.
 RING SPINNING
Ring spinning is a method of spinning fibres, such as cotton, flax or wool, to make
a yarn. The ring frame developed from the throstle frame. Ring spinning is a continuous process,
unlike mule spinning which uses an intermittent action. In ring spinning, the roving is first
attenuated by using drawing rollers, then spun and wound around a rotating spindle which in its
turn is contained within an independently rotating ring flyer. Traditionally ring frames could only
be used for the coarser counts- but they could be attended by semi-skilled labour.
The ring was a descendant of the Arkwright water Frame 1769. It was a
continuous process; the yard was coarser, had a greater twist and was stronger so was
suited to be warp. Ring spinning is slow due to the distance the thread must pass around
the ring, other methods have been introduced. These are collectively known as Break or
Open-end spinning.
A ring frame was constructed from cast iron, and later pressed steel. On each side of the
frame are the spindles, above them are the draughting (drafting) rollers and on top is a creel
loaded with bobbins of roving. The roving (unspun thread) passed downwards from the bobbins
to the draughting rollers. Here the back roller steadied the incoming thread, while the front roller
which was moving much faster pulled thread out (attenuated) forcing the fibres to mesh together.
The rollers are individually adjustable, originally by mean of levers and weights. The attenuated
roving now passes through a thread guide that is adjusted to be exactly above the spindle.
Thread guides are on a thread rail which allows them to be hinged out of the way for doffing or
piecing a broken thread. Like the hour and minute hands on a mechanical clock, the traveller,
and the spindle share the same axis but travel at different speeds. The spindle travels faster. The
bobbin is fixed on the spindle. In a ring a frame, the different speed was achieved by drag caused
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by air resistance and friction. The spindles rotate at 7000 to 8000 rpm, this spins the yarn. The
traveller, winds the yarn on the bobbin. The ring on the traveller is fixed on a lifting ring rail
which guides the thread onto the bobbin in the shape required: ie a cop. The lifting must be
adjusted for different cotton counts.
CONE WINDING
Ring spinning produces yarn in a package form called cops. Since cops from ring
frames are not suitable for further processing, the winding process serves to achieve
additional objectives made necessary by the requirements of the subsequent processing
stages.
Following are the tasks of winding process
 Extraction of all disturbing yarn faults such as the short, long thick ,long thin,
spinners doubles, etc
 Manufacture of cones having good drawing - off properties and with as long a length
of yarn as possible
 paraffin waxing of the yarn during the winding process
 introduction into the yarn of a minimum number of knots
 achievement of a high machine efficiency i.e high production level
BEAMING
The beam is a long cylinder with flanges and perhaps 600 threads are wound on
to it side-by-side. The machine is watched over by a "beamer". The full beam is very
heavy. In early days beaming was often done in the weaving mill but then tended to be
transferred to the spinning mill which would send the full beams to the weavers. Note that
this is more specifically called a "warper's beam"
SIZING
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The yarn is a little fragile for the rough treatment imposed by the weaving process
and a "size" is applied to make it more robust. A number of warper's beams (as above) are
placed at the back of the sizing machine and the yarn is drawn through and wound on to a
"weaver's beam". If the machine is fed by 8 warper's beams of 500 threads each then the
weaver's beam will have 4000 parallel threads.
CHAPTER – 2
2.1 OBJECTIVES OF THE STUDY
Primary Objective
The primary objective of the study is to study the modernization programme in

spinning mill at ATHISWAR TEXTILE MILL.
Secondary Objective
 To study about the present situation of various department.

 To study the various department functions and how it was earlier with regards to
variables.
 To study about the variables and its effects on modernization.
 To study about the improvements made and its advantage.
 To study about the labour savings and cost savings after modernization.
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2.2 NEED FOR STUDY
Modernization is the need of the hour to sustain and survive among the fittest. As such,
Athiwar mills is no exemption for this and it has been continuously in the process of
modernization. Whatever changes had come newly, the same were adopted to ensure that this
unit is in line with meeting the modernization changes and technological availability in the
country. Upgradation is taken in all facts, applicable to this industry, like upgradation, in
machines, labour skills, new training, implementation of new methods, measures etc….
So how these modernization process has helped the unit to upgrade its productivity,
quality et., after replacing these machines which were older models at the time of inception? A
detailed study has been taken up by me to assess the impact of the modernization process carried
out in this unit, by comparing the situation prevailing pre and post modernization, as part
fulfillment of my MBA programme.
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2.3 LIMITATION OF THE STUDY
 The major limitation was time factor it will not be possible to collect information from
more respondents within the limited period.
 The research work to find the current market situation is mostly based on the data
available in magazines and books.
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2.4 SCOPE OF THE STUDY
In today’s scenario, the upgradation of machineries became a vital role for cost advantage
and to produce quality products. The Research helps to view the gap analysis between the
present situation and the market situation. It gives an overall idea on the cost advantage,
efficiency, utilization etc…. by upgrading the machineries.
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2.5 RESEARCH METHODOLOGY
2.5.1 Research Design:
A research design is collection and analysis of data in a manner, which is

relevance to the research purpose with economy in procedure. The design adopted for the study
is descriptive in nature.
2.5.2 Research Problem:
A research problem in general, refers to some difficulty which a researcher experiences in

the context of either a theoretical or practical situation and wants to obtain a solution for the
same. A problem well defined is half solved. The research problem is to study the effectiveness
of modernization process carried out in Athishwar Textile Mills.
2.5.3 STATISTICAL TOOLS:
1. Simple Percentage Analysis.

2. Utilization of the machine capacity (%).
3. Efficiency of the machine (%).
Utilization of the machine capacity (%):
T * AP
Utilization of the machine capacity (%) = ------------ x 100.
H
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Where,
T-machine time for one component
AP-Actual production/shift
H-number of hours/shift
Efficiency of the machine (%):
Actual output
Efficiency of the machine (%)= ------------------------- x 100.
Total output
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2.6 SOURCES OF DATA
The sources of data may be classified into
a) Primary source
b) Secondary source
2.6.1 Primary Sources
Primary Sources are original sources from which the researcher directly collects
data that have not been previously collected. Primary data are first hand information collected
through various methods such as observation, interviewing, mailing, through questionnaire, etc.
In this study the primary source of data is collected through Observation and
Interview with the senior officials.
2.6.2 Secondary Sources
These are sources containing data which have been collected and compiled for
another purpose. The secondary sources consists of readily available compendia and already
compiled statistical statements and reports whose data may be used by researchers for their
studies. E.g. census reports, annual reports and financial statements of companies.
In this study the secondary source of data is collected through Log book, various
manuals, periodic magazines, Journal and books from library.
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CHAPTER – 3
MODERNIZATION DETAILS AS PER THE PROCESS FLOW
3.1. BLOWROOM:
TABLE: 3.1
PARTICULARS BEFORE AFTER

MODERNIZATION MODERNIZATION
Make/model of the machine NSE TRUMAC

Year 1962 1994
Production in Kgs/8hrs 1416 2925
Efficiency % 84.6 89.0
Utilization % 93.9 93.9
3.2 CARDING:
TABLE: 3.2

Make/model of the machine LRC1/2,LRC1/3 TRUMAC DK740

Year 1983 1994
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3.3 LAP MACHINE:
TABLE: 3.3

Make/model of the machine TOKAI LAKSHMI LE 2/4a

Year 1967 2000
3.4 COMBER:
TABLE: 3.4

Make/model of the machine RIETER LAKSHMI RIETER 6/S

Year 1967 1992
Production in Kgs/8hrs 83.4 155.0
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3.5 DRAWING:
TABLE: 3.5

Make/model of the machine TEXMACO HOWA DFK- LAKSHMI RIETER

2CD RSB-851
Year 1992 1995
3.6 SIMPLEX:
TABLE: 3.6

Make/model of the machine LAKSHMI RIETER GS LAKSHMI RIETER LF

1400A
Year 1971 2000
3.7 SPINNING:
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TABLE: 3.7

Make/model of the machine LAKSHMI RIETER DJ-5 LAKSHMI RIETER 6/S

Year 1972 2000
3.8 CONE WINDING:
TABLE: 3.8

Make/model of the machine TEXTOOL-RT95 SCHAFHORST-238

MURATEC-7.7
Year 1979 1994
Production in Kgs/8hrs 4.6 15.12
CHAPTER-4
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INTERPRETATION & ANALYSIS
A textile mill is a unit where production of yarn by adopting the spinning process is
carried out. But this function goes on effectively until the non-technical support is offered to this
technical area.
Hence, the function of this unit like other technical units had to depend upon the non-
technical functions also. Accordingly, the unit functions are divided into two areas like personnel
and administration and technical.
DETAILS OF UTILIZATION, PRODUCTIVITY & EFFICIENCY-PRE & POST

MODERNIZATION (BLOWROOM):
DESCRIPTION BEFORE AFTER

1991 1992 1993 avg 1995 1996 1997 avg
89.6 87.2 90.3 89.0 93.75 93.2 94.8 93.9

Utilization in %
1442 1420 1388 1416 2957 2900 2919 2925

Productivity in kgs / 8hours
85.4 84.6 83.8 84.6 93.75 94.2 93.8 93.9

Efficiency (%)
Note: - Modernization of this aspect was carried out in the year 1994. Data preceding 3 years
and 3 years after modernization are taken for the study.
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96
94
P
E 92
R 90
C
E 88
N
T 86
UTILIZATION
A 84
G EFFICIENCY
E 82
80
%
78
1990 1991 1992 1993 1994 1995 1996 1997 1998
YEAR
3500
3000
2500
2000
PRODUCTION IN KGS/8HOUR
1500
PRODUCTIVITY
1000
500
0
1990 1991 1992 1993 1994 1995 1996 1997 1998
YEAR
INFERENCE:
(i).Utilization:
The utilization has increased from 89% to 93.9% which is a steep growth.
(ii).Efficiency:
The efficiency has increased from 84.6% to 93.9%.
(iii).Productivity:
The productivity has increased from 1416kgs to 2925kgs.
31

MODERNIZATION (CARDING):

1991 1992 1993 avg 1995 1996 1997 avg
90.2 91.6 89.8 90.5 92.0 91.6 92.3 92.0

Utilization in %
104 112 108 108 328 336 338 334

83.2 82.1 81.8 82.4 90.2 89.8 90.0 900

Efficiency (%)
94
92
P 90
E
R 88
C
E 86
N
T 84 UTILIZATION
A
G 82 EFFICIENCY
E 80
% 78
76
1990 1991 1992 1993 1994 1995 1996 1997 1998
YEAR
32
400
350
300
250
PRODUCTION IN KGS/8HOUR 200

150 PRODUCTIVITY
100
50
0
1990 1991 1992 1993 1994 1995 1996 1997 1998
YEAR
INFERENCE:
(i).Utilization:
The utilization has increased from 90.5% to 92.0% which is a steep growth.
(ii).Efficiency:
(iii).Productivity:
33

MODERNIZATION (LAP MACHINE):

1997 1998 1999 avg 2001 2002 2003 avg
90.4 91.2 90.2 90.6 99.1 98.9 99.0 99.0

Utilization in %
640 666 630 645 1135 1082 1082 1108

52.1 52.6 51.4 66.8 66.8 68.2 68.1 67.5

Efficiency (%)
120
P 100
E
R 80
C
E
N 60
T UTILIZATION
A
G 40 EFFICIENCY
E
20
%
0
1996 1997 1998 1999 2000 2001 2002 2003 2004
YEAR
34
PRODUCTIVITY
1200
1000
800
600 PRODUCTIVITY
PRODUCTION IN KGS/8HRS
400
200
0
1996 1997 1998 1999 2000 2001 2002 2003 2004
YEAR
INFERENCE:
(i).Utilization:
(ii).Efficiency:
(iii).Productivity:
35

MODERNIZATION (COMBING):

1989 1990 1991 avg 1993 1994 1995 avg
93.1 94.2 94.8 94.0 98.2 97.4 97.2 97.6

Utilization in %
80.4 84.2 85.6 83.4 157 152 156 155

72 71.4 73.6 72.3 82.4 82.0 83.1 182.5

Efficiency (%)
120
P 100
E
R 80
C
E
N 60
T UTILIZATION
A
G 40 EFFICIENCY
E
20
%
0
1988 1989 1990 1991 1992 1993 1994 1995 1996
YEAR
36
PRODUCTIVITY
180
160
140
120
100
PRODUCTIVITY
PRODUCTION IN KGS/HOUR 80
60
40
20
0
1988 1989 1990 1991 1992 1993 1994 1995 1996
YEAR
INFERENCE:
(i).Utilization:
The utilization has increased from 94% to 97.6% which is a steep growth.
(ii).Efficiency:
(iii).Productivity:
The productivity has increased from 83.4kgs to 155kgs.
37

MODERNIZATION (DRAWING):

1992 1993 1994 avg 1996 1997 1998 avg
95.2 94.8 93.9 94.6 97.2 98.1 98.3 97.8

Utilization in %
924 890 880 898 1021 1050 1065 1045

83.2 82 81.6 82.2 88.6 89 90.1 89.2

Efficiency (%)
120
P 100
E
R 80
C
E
N 60
T UTILIZATION
A
G 40 EFFICIENCY
E
20
%
0
1990 1991 1992 1993 1994 1995 1996 1997 1998
YEAR
38
PRODUCTIVITY
1200
1000
800
600 PRODUCTIVITY
PRODUCTION IN KGS /8HOUR
400
200
0
1990 1991 1992 1993 1994 1995 1996 1997 1998
YEAR
INFERENCE:
(i).Utilization:
(ii).Efficiency:
(iii).Productivity:
39

MODERNIZATION (SIMPLEX):

1997 1998 1999 avg 2001 2002 2003 avg
96.4 97.2 96.2 96.6 96.2 97.2 97.4 96.75

Utilization in %
335 342 338 338 436 441 444 440

84.2 85.6 83.2 84.3 88.2 86.1 86.4 87.25

Efficiency (%)
100
P 95
E
R
C 90
E
N
T 85 UTILIZATION
A
G EFFICIENCY
E
80
%
75
1996 1997 1998 1999 2000 2001 2002 2003 2004
YEAR
40
PRODUCTIVITY
500
450
400
350
300
250 PRODUCTIVITY
PRODUCTION IN KGS/8HOURS
200
150
100
50
0
1996 1997 1998 1999 2000 2001 2002 2003 2004
YEAR
INFERENCE:
(i).Utilization:
(ii).Efficiency:
(iii).Productivity:
41

MODERNIZATION (SPINNING):

1997 1998 1999 avg 2001 2002 2003 avg
98 98.1 98.2 98.1 98.2 98.4 98.5 98.3

Utilization in %
90 91.1 90.6 90.6 92 93.1 93.2 92.6

Efficiency (%)

Counts
262 258 263 261 286 290 291 288
16s
190 188 191 190 215 218 218 216
20s
145 148 147 147 160 164 164 162
30s
100
98
P
E 96
R
C 94
E
N 92
T UTILIZATION
A 90
G EFFICIENCY
E 88
% 86
84
1996 1997 1998 1999 2000 2001 2002 2003 2004
YEAR
42
350
300
250
200
PRODUCTION IN KGS/8HOUR 16s
150
20s
100 30s
50
0
1996 1997 1998 1999 2000 2001 2002 2003 2004
YEAR
INFERENCE:
(i).Utilization:
(ii).Efficiency:
(iii).Productivity:
The productivity for the counts 16s: increased from 261kgs to 288kgs
20s: increased from 190kgs to 216kgs
30s: increased from 147kgs to 162kgs
43

MODERNIZATION (WINDING):

1991 1992 1993 avg 1995 1996 1997 avg
95.4 96.1 96.4 96.0 97.2 96.8 96.8 96.9

Utilization in %
64.2 65.1 64.6 64.6 75.4 74.2 74.3 74.6

Efficiency (%)

Counts
5.7 5.72 5.69 5.7 18.61 18.72 18.72 18.63
16s
4.58 4.62 4.60 4.6 14.88 15.3 15.3 15.12
20s
3.01 3.20 3.12 3.11 9.93 9.92 9.92 9.89
30s
120
P 100
E
R 80
C
E
N 60
T UTILIZATION
A
G 40 EFFICIENCY
E
20
%
0
1996 1997 1998 1999 2000 2001 2002 2003 2004
YEAR
44
20
18
16
14
12
10
PRODUCTION IN KGS/8HOURS 16s
8 20s
6 30s
4
2
0
1996 1997 1998 1999 2000 2001 2002 2003 2004
YEAR
INFERENCE:
(i).Utilization:
(ii).Efficiency:
(iii).Productivity:
The productivity for the counts 16s: increased from 5.7kgs to 18.63kgs
20s: increased from 4.6kgs to 15.126kgs
30s: increased from 3.11kgs to 9.89kgs

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1

INTRODUCTION TO THE STUDY

1.1 ABOUT THE STUDY

1.1.A INTRODUCTION TO MODERNIZATION PROGRAMME

Modernization is interpreted in the restricted sense of replacement of the old machines

1.1 ABOUT THE INDUSTRY

Strengths of the Textile Industry:

The following are few strengths of the Indian Textile Industry:

Weaknesses of the Textile Industry:

1.2 ABOUT THE COMPANY

ATHISWAR TEXTILE MILL manufactures several kind of cotton yarns in cone, in

A brief profile of the company is given below:

Name of the Company : ATHISWAR TEXTILE MILL

Year of Establishment : 2003

Address of the company : K.Ayyampalayam,

Installed capacity : 11400 spindles

Nature of the Business : Manufacturing of cotton Yarn in cone

Type of Industry : Textile

Paid up capital : Rs.4 Crores

Loan from Bank : Rs.1Crores

Quality : 40’s, 30’s

Number of workers : 300

FACTORY OFFICIER ADMINISTRATIVE OFFICIER

SPINNING MASTER POWER HOUSE

MASTRIES SHIFT SUPERVISORS

SHIFT CLERKS OFFICE ASSISTANT

COUNT = Thickness of the Yarn Produced from cotton

Blow room installations consists of a sequence of different machines to carry out

Basic operations in Blowroom :

 Opening in blowroom means opening into small flocks.Technological operation of

Tex is the weight in grams of 1 km of yarn

High production in carding to economize the process leads to reduction in yarn

 to open the flocks into individual fibres

The two main ways to card fibers are by

There are two types of feeding to the cards

 Piercers would mend broken threads and

Following are the tasks of winding process

2.1 OBJECTIVES OF THE STUDY

The primary objective of the study is to study the modernization programme in

 To study about the present situation of various department.

2.2 NEED FOR STUDY

2.3 LIMITATION OF THE STUDY

2.4 SCOPE OF THE STUDY

2.5 RESEARCH METHODOLOGY

2.5.1 Research Design:

A research design is collection and analysis of data in a manner, which is

2.5.2 Research Problem:

A research problem in general, refers to some difficulty which a researcher experiences in

2.5.3 STATISTICAL TOOLS:

1. Simple Percentage Analysis.

Utilization of the machine capacity (%):

2.6 SOURCES OF DATA

The sources of data may be classified into

2.6.1 Primary Sources

2.6.2 Secondary Sources

MODERNIZATION DETAILS AS PER THE PROCESS FLOW

PARTICULARS BEFORE AFTER

Make/model of the machine NSE TRUMAC