Project Nilesh

8/2/2019 Project Nilesh

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The

Summer Internship Project Report

On

Organizational Overview

At

BIRLA VXL LIMITED

FABRICfor that GREAT SUIT

Submitted by

KHANDHAR NILESH

MBA Sem II

Academic Year : 2010-2012

T.N. RAO COLLEGE RAJKOT

Guided by,

SHOIAB A. LOHANI

Submitted to,

GANESHPRASAD SINGH SIR


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EXECUTIVE SUMMARY

The textile sector is one of the fastest growing sectors in the economy. There are many

players in this sector but DIGJAM is a step ahead of them all. DIGJAM is committed to

satisfy customers by providing quality products and services, which give highest value

for money. They believe that their employees are their most important assets through

which they can reach the top in each field they venture into.

ITS WHO YOU AREthey commit themselves to continuous growth so as to fulfill

the aspirations of the customers, employees and shareholders.

The whole project is based on understanding the two Ps of marketing i.e., Product and

Promotion.

I am really very thankful to the management at DIGJAM for giving me to an opportunity

to undertake a project work in their organization. I hope that the work done by me is

satisfactory.


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CORPORATE

PORTFOLIO


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CORPORATE PROFILE

REGISTERED OFFICE:

DIGJAM Limited,

Aerodrome Road,

Jamnagar 361 006

Gujarat.

CORPORATE OFFICE:

DIGJAM imited

801, Bhikaji Cama Bhawan 11,

Bhikaji Cama Place,

New Delhi 110 066,

India

UK Representative Office

DIGJAM Limited

18 King shill Avenue Harrow,

Middlesex HA3 8JP,

United Kingdom

Tel: .(44) 208 907 8687


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Fax: (44) 208 909 2527

E-mail :[email protected]

OTHER OFFICES:

Delhi

Mr. Amit Gupta

DIGJAM Limited, 501, 2nd Floor, Krishna Gali,Katra Neel, Chandni Chowk

New Delhi 110006

Punjab

Mr. Balbir Sharma / Mr. Alok Pachauri

DIGJAM Limited, 3 Kairon Market, 2nd Floor,Hall Bazar

Amritsar 143006

West Bengal

Mr. Ashok Bodhania / Mr. N K Sharma

DIGJAM Limited, 9/1 R N Mukherjee Road

Kolkata 700001

PRINCIPAL OPERATING DIVISION:

Aerodrome Road, DIGJAM LIMITED,

Jamnagar 361 006

Gujarat

REGISTERED AND SHARE TRANSFER AGENTS:

MCS Limited,

77/2A, Hazra Road, 3rd & 5th Floor, Kolkata 700 029
mailto:[email protected]:[email protected]:[email protected]:[email protected]


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Tel (033) 2476 7350 54, 2454 1892 93

Fax: (033) 2454 1961, 2474 7624

e-mail: mailto:[email protected]

AUDITORS:

Deloitte Haskins & Sells

BANKERS:

o UCO Banko Bank of India

o Bank of Baroda

o PNB

o Punjab & Sind Bank

o SBI

o SBS

o

Standard Chartered Banko UBI

BOARD OF DIRECTORS:

o S. K. Birla Chairman

o Siddharth Birla Vice Chairman

o

N. Lalbhaio R.K. Chaudhary

o Dr. G. Goswami

o Gauri Kumar

o G. Momen

o C. Mukherji

o P. K. Pujari
mailto:[email protected]:[email protected]:[email protected]


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EXECUTIVES:o C.L Rathi M. D

o M. R. Surekha Co. Secretary and Executive V. P (Legal)

o R. K. Kedia President

o Virendra Gupta V.P. (Exports)

o Ravinder Sharma V.P. (Sales and Marketing)

o P.K. Das V.P. (Exports) and Business Head

STOCK EXCHANGE LISTING:

o More than 93000 shareholders listed in

o BSE

o NSE

o Kolkata Stock Exchange

o Delhi Stock Exchange

o

Saurashtra Kutch Stock Exchange


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MISSION & VISION OF COMPANY

MISSION

To be an enterprise acclaimed for its products & services among peers and customeralike, by having responsible workforce & through best available technology

VISION

To be the clear favorite & premium contender in our principal market.


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INDUSTRY OVERVIEW

Textile Industry in India is the second largest employment generator after agriculture. It holdssignificant status in India as it provides one of the most fundamental necessities of the people.Textile industry was one of the earliest industries to come into existence in India. In fact Indian

textile industry is the second largest in the world, second only to China.

Textile Industry is unique in the terms that it is an independent industry, from the basic requirementof raw materials to the final products, with huge value-addition at every stage of processing. Textileindustry in India has vast potential for creation of employment opportunities in the agricultural,industrial, organised and decentralized sectors & rural and urban areas, particularly for women.

Till the year 1985, development of textile sector in India took place in terms of general policies. In1985, for the first time the importance of textile sector was recognized and a separate policystatement was announced with regard to development of textile sector. .

India Textile Industry is one of the leading textile industries in the world. Though was predominantlyunorganized industry even a few years back, but the scenario started changing after the economicliberalization of Indian economy in 1991. The opening up of economy gave the much-needed thrustto the Indian textile industry, which has now successfully become one of the largest in the world.India textile industry largely depends upon the textile manufacturing and export. It also plays a majorrole in the economy of the country. India earns about 27% of its total foreign exchange throughtextile exports. Further, the textile industry of India also contributes nearly 14% of the total industrialproduction of the country. It also contributes around 3% to the GDP of the country. India textileindustry is also the largest in the country in terms of employment generation. It not only generates

jobs in its own industry, but also opens up scopes for the other ancillary sectors. India textile industry

currently generates employment to more than 35 million people. It is also estimated that, the industrywill generate 12 million new jobs by the year 2010.

In the year 2000, National Textile Policy was announced. Its main objective was:

To provide cloth of acceptable quality at reasonable prices for the vast majority of thepopulation of the country,

To increasingly contribute to the provision of sustainable employment and the economicgrowth of the nation,

To compete with confidence for an increasing share of the global market.


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Various CategoriesIndian textile industry can be divided into several segments, some of which can be listed as below:

Cotton Textiles Silk Textiles Woolen Textiles Readymade Garments Hand-crafted Textiles Jute and Coir

The IndustryIndia textile industry is one of the leading in the world. Currently it is estimated to be around US$ 52billion and is also projected to be around US$ 115 billion by the year 2012. The current domesticmarket of textile in India is expected to be increased to US$ 60 billion by 2012 from the current US$

34.6 billion. The textile export of the country was around US$ 19.14 billion in 2006-07, which saw astiff rise to reach US$ 22.13 in 2007-08. The share of exports is also expected to increase from 4% to7% within 2012. Following are area, production and productivity of cotton in India during the last sixdecades

Strengths

Vast textile production capacity Large pool of skilled and cheap work force Entrepreneurial skills Efficient multi-fiber raw material manufacturing capacity Large domestic market Enormous export potential Very low import content Flexible textile manufacturing systems

Weaknesses

Increased global competition in the post 2005 trade regime under WTO Imports of cheap textiles from other Asian neighbors Use of outdated manufacturing technology Poor supply chain management Huge unorganized and decentralized sector High production cost with respect to other Asian competitors


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Current Facts on India Textile Industry

India retained its position as worlds second highest cotton producer.

Acreage under cotton reduced about 1% during 2008-09. The productivity of cotton which was growing up over the years has decreased in 2008-09. Substantial increase of Minimum Support Prices (MSPs). Cotton exports couldnt pick up owing to disparity in domestic and international cotton

prices. Imports of cotton were limited to shortage in supply of Extra Long staple cottons.

Textiles Major Companies

AlokTextile

Indianra on

GTNtextile

Century

Gokuldas

Morarjee

SardaTextile

Digjam

Verdhman

Raymond

Arvindmill

Major

la ers


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COMPANY HISTORY / INTRODUCTION

DIGJAM Limited, an S K Birla Group Company, began its activities nearly 60 years back inJamnagar, Gujarat. Since then, it has been catering to the ever-growing demands of the Clothing andFashion industry, in the domestic as well as the international markets.

DIGJAM Limited is a leading textile company in India, manufacturer of fabrics for suiting andcasual wear. In recent years, the company restructured its business portfolios to focus as a textilecompany manufacturing and marketing fabrics and ready-to-wear clothing under its own brands.

A complete vertically integrated plant, DIGJAM has ultra modern production facilities to convertwool tops to finished fabrics through different processes of Dyeing, Spinning, Weaving and

Finishing using state-of-the-art machinery imported from France, Germany, Switzerland and Italy.Stringent quality checks at every stage and process enabled DIGJAM to bag the prestigious ISO9001 certification. Keeping pace with the complex requirements of the industry, DIGJAMexpanded its production capacity to over 5 million meters, of which 35%-40% (approximately) isexported to major countries across the globe.

Andersen Consulting, a leading management and corporate advisors agency, undertook a majorreview of the operational parameters of our textile company. Following a thorough review of theoperating and marketing practices, recommendations were made which now form the basis of ourstrategic marketing and manufacturing thrusts spanning the coming 3-4 years. The company has alsoinitiated steps to strengthen its organization and induct the youth and skills necessary to attain results

from this strategic shift-cum-consolidation exercise.

While the company lays uniform stress on all fundamental aspects such as quality, designs and cost-friendliness for products under all its brands, DIGJAM is undoubtedly its premium fabrics brand.DIGJAM has a high-end fabric brand presence in the domestic market, reputed for its finish andquality. The company manufactures over 3000 design-shade combinations each year in Light Wool,Polyester Wool and Woolen fabrics for the DIGJAM brand alone. Constant research on designsensures creation of innovative future trends. In the new millennium, DIGJAM introduced super-premium fabrics designed by European experts (with whom we work regularly and extensively)comprising fine wool yarn of Super 150s and Super 120s and occasionally blended with exotic fiberslike Silk or Cashmere.

Dressing in India has come of age - rising affluence levels, increased media exposure of internationalfashions and a growing tendency towards self-indulgence have all contributed to it. The all roundimpact is visible with the influx of international, and domestic products and brands in both, formaland casual wear. Indian customer has choice today, but one where we are determined to make andsustain our mark.


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The DIGJAM brand will increasingly reflect both tradition and modernity in its positioning, productrange and marketing approach. We intend to position the brand as the clear favorite for a wider, butdemanding clientele with special emphasis on becoming the preferred premium choice for theyouthful consumer. This segment offers a high potential in terms of market size and also presents atougher challenge to us in terms of providing satisfaction. DIGJAM'S superior product quality is at

par with global standards and many of the world's best readymade brands use fabrics produced by us.A major proportion of our output is exported to USA, Europe, Middle East and Far East. This bodeswell for our future as our preeminent position as one of the largest manufacturer of textiles fromIndia.

Our marketing thrust will over time impact all facets of the brand's interface with consumers,including new product introductions, consumer promotions and the rich retail experience. It must benoted that the DIGJAM brand has been ranked at no. 4 among the top Apparel brands of our country,in a study conducted by the prestigious Economic Times newspaper of the Times of India group.Apparel category comprised of all the top Fabric brands as well as the Readymade Garment brandsavailable in the country. This particular study at the consumer level at a national level was conducted

to find out India's Most Trusted Brands.'

DIGJAM products and their ranges are available at its exclusive showrooms and over 3000 otherretail outlets across the country.


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MANAGEMENT ORGANIZATION STRUCTURE

Chart 1: Organization Chart (1)

Board of Directors

Managing Directors

President

Vice President

Export & Head

universal

Vice President

Technical

Vice President

Sales &

marketing

Vice President

Legal

GM

Personnel

GM

Sales & Mktg.

GM

Finance

GM Corp.

Finance

Company

Secretary

Area

Manager


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DOMESTIC SALESVP (S&M)

(Shri Ravinder Sharma)


East West South North

SR.Manager

(Shri Rajesh Sharma)

DY.GM

(Shri Sharad Goel)

GM(Shri Amit Gupta)

SR.MANAGER

DY. MANAGER / ASST. MANAGER

SALES OFFICERS


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SELLING REPRESENTATIVES / AGENTS

DIGJAM

SRs SALES TEAM

WHOLESALERS/ EXCLUSIVE MULTIDISTRIBUTORS SHOWROOMS BRAND

OUTLETS

TAG DEALERS

CONSUMER



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General information

1 Name of the firm DIGJAM LTD.

2 Brand name DIGJAM3 Years of establishment4 Form of organization Public Ltd. Co.5 Location of Unit DIGJAM LTD.

Aerodrome road, Jamnagar. 361006

(Gujarat-India)

6 Tel. No. +91(0288)2712972/73

7 Fax No. +91(0288)27129918 E-mail [email protected] Web site www.digjam.co.in

10 Corporate Office 801, Bhikhaji Kama Bhavan, New Delhi-110066

11 Promoter S.K. Birla

12 Certified ISO 900113 Board O Directors S.K. Birla (Chairman)

Siddharth Birla (Vice Chairman)

A.N. Lalbhai

Arvind Agrawal

R.K. Chaudhary

Dr. G. Goswami

N.L.Hamirwasia C.L. Rathi(MD)

Rajiv Sharma (Executive Director& Chief Operating Officer)

14 Auditor Kimji Kunvarji & Co., (C.A.) Mumbai.15 Bankers UCO Bank

Bank Of India Bank Of America

Bank Of Baroda Punjab National Bank

State Bank Of Saurashtra Standard Chartered Bank
mailto:[email protected]://www.digjam.co.in/http://www.digjam.co.in/mailto:[email protected]


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Union Bank Of India

State Bank Of India16 Clients Aditya Birla Nuvo

Airport Authority Of India

Alcock Ashdown (Gujarat) Ltd. Arvind Brands

Arvind Clothing Ltd. Assam Rifles

Banaras Hindu University Bharat Heavy Electronic

Ltd.(BHEL)

Bharat Petroleum Corp. Ltd.

Birla Institute Of Technology

Bombay Hospital

Castrol (India) Ltd.

Gujarat Alkalies & ChemicalsLtd.

Gujarat Industrial Power Co.Ltd.

Gujarat Narmada ValleyFertilizer Corp.

Gujarat State Fertilizer Corp. Hindustan Motors Ltd.

Hindustan Petroleum Corp. Ltd.

ICICI Ltd.

INDAL

Indian Air Force

Indian Aluminum Co. Ltd.

Indian Farmers Fertilizers Co-Op Ltd.

Indian Oil Corporation (GujaratRefinery) ITC Ltd.

ICFAI Business School,Ahmadabad

Mohan Clothing Company.

M.S. Patel Institute Ofmanagement, M.S. University

Mysore Cement ltd.

NCL Naval H Q.


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Ordinance Clothing Co.

Reserve Bank Of India SAIL

Suarashtra Chemicals

Shoppers Stop Ltd. Sports & Leisure Apparels Ltd.

Taj Trade Transport Co. Ltd.

Tamil Nadu Police

Tata Industries Ltd.

Tata Timken Ltd.

Tehri Hydro Development Corp.Ltd.

17 Company Logo ITs who you are18 Production Capacity Year:- 73,00,000 Meters

Day:- 20,000 Meters19 Export 50%

20 Import 50%21 Exported Country U.S.A., Canada. U. K., Europe, Middle

East & Far East , Japan , Australia etc.


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DIGJAM ACHIEVERS UNLIMITED (DIACHS) CLUB

A unique and one of kind exclusive club created for the first time in the industry. Based on

certain parameters and criteria, top Wholesalers, Retailers and Digjam Retail Showrooms

were selected for the DIACHS Club.

Objective is to work together for mutual benefit and increase our business. To reward the

good and consistent performers and to enter into a committed, long-term relationship with

the Dealers. Membership valid for 1 year. The members have the following benefits:

Special incentive on turnover on achievement of a minimum turnover target (based

on certain parameters).

Special Qualities / Design Selection: Special qualities to be developed for Achievers

Unlimited members. Participation and involvement of club members for range

development.

Special samples of selected / fast moving qualities to be provided to club members.

Achievers Unlimited Members Meet - To participate in DIACHS Meet organized

once in a year. In such functions, the top performing members to be awarded and

honored by top management.

Special Service: To give priority to them in order procurement and execution. Suitlengths to be dispatched to club members through courier on paid basis.

Special Certificate recognizing members as part of the Digjam Achievers Unlimited

family.

The formation of this unique club was made know to the achievers at Dealers Meet

organized at The Intercontinental, Goa in September, 2004.
http://www.digjam.co.in/Web/digjam_achievers.aspxhttp://www.digjam.co.in/Web/digjam_achievers.aspxhttp://www.digjam.co.in/Web/digjam_achievers.aspx


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AWARDS & RECOGNITIONS

Table 1

Awards & Certification Year

1) Confidence in Textiles 2007

2) ISO 9001:2000 2007

3) Lycra Assured 2005

4) Export House Certificate 2004

( Source:www.digjamsuiting.com)

Credentials

Awards:

Highlights - Why Digjam is Ahead :

1. Using the best technology and machines available, Digjam has achieved the ISO

9001 international quality Certification.

2. Impressive capability: The present production capacity of over 20,000 meters of

woolens per day is one of the highest in the industry.

3. Exporting nearly 35% if its total production. Digjam textiles are now in use in the

U.S., Canada, U. K., Europe, Middle East Far East, Japan & Australia.

4. For four consecutive years, DIGJAM Limited has received the highest ExporterAward, in the woolen worsted category, from the export Promotion Council, a Govt.

of India Undertaking.

5. Digjam is a Unit of the trusted Birla Group of Industries with a world-wide presence

and strong reputation.

6. The first and only worsted mill in India to be awarded the status of "ACCREDITED

MILL" from the internationally renowned DuPont.
http://www.digjamsuiting.com/http://www.digjamsuiting.com/http://www.digjamsuiting.com/http://www.digjamsuiting.com/


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7. Woolmark & Wool blend mark license from International Wool Secretariat.

Digjam has been awarded the status of "ACCREDITED MILL" from the internationally

renowned DuPont and is now a part of the elite LYCRA ASSURED Network, which is the

world's leading supply chain for innovative, quality stretch fabrics.

In this difficult business environment, alliances are becoming more important than ever and

the ability to differentiate one's company is even more crucial. These two business needs

are the drivers behind our decision to be part of the exclusive LYCRA ASSURED

Network.

The goal is to create value in the LYCRA ASSURED Network as a whole, thus making it

the automatic first stop for the world's leading buyers looking for premium stretch solutions

and the latest fiber and fabric innovations and new concepts. The expanded support and

services planned by DuPont as part of the value delivered by membership in the Network

are mentioned below:

Early access to new DuPont technologies and exciting innovations not only for Lycra, but

also for other important products like Teflon, Tactel, Coolmax, Cordura, Supplex,

Thermolite, and technical support.

New revenue growth opportunities.

Significant cost and competitive advantages.

Constant promotion of LYCRA ASSURED Network benefits and the products of its

partners to key buyers.

Keeps us at the forefront of stretch innovations.

New global sourcing options - from fiber through garment.

ATS fabric library.

Exclusive or priority access to market research. Participation in exclusive retail and

consumer promotions.


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FLOW CHART OF DIGJAM LIMITED

Sales &marketing

department production

department

Prod. Planning& control

department

Exportdepartment

Financedepartment

Humanresourcedepartment


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INTRODUCTION

Since production is the process of converting inputs into finished goods and services, it must bemanaged. It deals with proper use of manpower and machinery for transforming raw material intofinished product.

Production management deals with decision making related to the production process, so as to the

resulting goods and services produced according to the specification, in the amounts and by thescheduled demanded and at minimum cost.

Production is the process to create or manufacture the goods and services. It is the main process by

which an organization sale their product after the production of goods and services.

Production is a function of planning, organizing and controlling through which a unit convert the rawmaterials into finished goods. It includes the following:

Raw materialsProcurement and storage of raw materialsManufactured products

DIGJAM Ltd. has a drastic manufacturing unit in Jamnagar with a working environment. It ismainly producing the fabric clothes through various process of production with starts from greycombing and ends with finished product that is called fabric.

Plant location

Section of plant is very sturdy job for any production unit because ultimately every organizationwants to reduce their cost of production and also wants to get every facility near to the place as wellas a good layout where it will produce its products.

DIGJAM Ltd. Is located as a coastal region of Jamnagar at Gujarat because this land was given byH.H.Jamsaheb and which is helpful to import raw material like wool and export the finished productand also helpful for local transportation because of the remote town. Near to the plant all the facilityare available like electricity, school, bank, stores, hospital, market, transportation, economical

atmosphere, labors, machineries and securities.

The total weaving capacity of the plant is 7 million meters p.a. The plant spread over 47 acres,employees 515 executives and a dedicated force of 1600 workers.


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Raw materials and products

Raw material is the basic need for a manufacturing unit through which the production process andoperation cycle run.

In DIGJAM Ltd. The raw materials are two types :-

MERINO wool (natural fiber) Polyester

1. MERINO woolMERINO wool is purchased mainly from Australia, South Africa and New Zealand.

Wool is natural fiber which is used to make the fabrics in DIGJAM. This wool is testedand certified for its quality by IWTO (international wool testing organization). Theconsignment from Australia must have the Australian wool testing certificate (AWTCrecognized).

2. Polyester:-Polyester is manmade fiber comes in DIGJAM from reliance and IOCL pondichery.Some variety of polyester is imported from Germany. Types of polyester used inDIGJAM are

a) Semi dullb) Sparkling whitec) Normal whited) Black


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PRODUCTION PROCESS

DIGJAM Ltd. Completely vertically integrated plant located in Jamnagar has ultra modernproduction facilities to convert wool top to finished fabrics through different process of greycombing, dyeing, spinning, weaving, folding and finishing using state of the art machinery imported

from France, Germany, Italy, Switzerland, Belgium and south Korea. The company manufacturesmore than 1000 quantities in over 3000 design shades combination each year in light wool andwoolen fabrics for the DIGJAM brand alone and also free with practically no pollution.

PRODUCTION PPOCESS

Dyeing

Spinning (Reduce thickness of roving)

Weaving

Finishing (chemical and mechanical)

Grey combing (Top ready)

Product prepare

Folding (inspection)

Length cutting and scathing

Stamping

Ready for export and domestic


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GREY COMBING DEPARTMENT

Greasy wool has import from South Africa and Australia.Order has been received in one and half month. Wool has reached at Bombay port and then by truck

it reached at DIGJAM. 20tone wool is in one ship.

The raw material (wool) received as per specification in different micron like 17.5 micron,18.5micron,19.5 micron and 22.5 micron. Micron has been measured in terms of length.17.5 is standardmicron as length wise.

Process of woolen fabric process of polyester

Fiber separation

Stretching

Releasing

CuttingGill Sliver(Combin

Card Sliver

(Gillin

Scoured wool

(Carding)

Raw-MaterialScourin

Tow cutting

Top

Gilling (3times)

Top


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Objectives of grey combing:-

To clean the greasy wool Increase the mean length of the fiber

Make in to the TOP form

This is the very first and initial division as a part of the whole process. In the grey combingthe raw material is greasy wool and polyester. So grey combing convert the wool andpolyester inform of top which made by sliver. So here wool is import from countries likeAustralia, south Africa and New eland and polyester supplied from RIL, IOCL and alsoimport from Germany. So grey combing has two ways to make the sliver:-

First from wool Second from polyester

First from wool

To remove all the undesired things and make the wool pure and ready for dye, there are fourprocesses to make top form:-

1) scouring2) Carding3) Gilling4) Combing

1) Scouring

This is the process by which dirt, grease, perspiration, salt and vegetable matters are removed fromthe wool by washing it in non-ionic detergent (namely IGSURF and ALPHOX) and soda ash. Thiswhole process contains five bowls, from which three bowls are used for washing the wool withdetergent (at 62C,60C,60C temperature respectively) and rest two is used for washing wool withclean hot water (at 55C temperature)


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The process of scouring contains four steps;

2) Carding

This is the process in which BURR and SHODDY are removed and cleaned it properly. Thewool have to pass over thirty five roller in carding process.Main object of carding is to remove vegetable matter, opened up bunches and fleeces for separationof fibers, conversion of web to silver form.

3) Gilling

Gilling is the process done before combing. In this, there is a comb like structure to blend differentquality of card sliver together and make fiber parallel to one another. The multiple fibers are mixedto reduce the variation in quality i.e. average length and fiber fineness in lot.Main function of Gilling is to make uniform sliver by drafting,

Three consecutive Gilling is given in the process to reduce the variation in quality the fibers;

Gilling-1 (ten carded slivers are fed to the machine and form one sliver)

Gilling-2 (5 slivers are fed)

Gilling-3

4) Combing

Combing process is done to remove remaining vegetable matters, naps and short fibers which can

create problems in spinning to generate drafting weave. The final product of combing is TOP andby product called NOIL.

Reopening (wool opened manually is reopened)

Washing (wool is washing with detergent & warm water

Squeezing (Pressure is given to the washed wool)

Drying (wool goes for dry in dried chamber at 90 C to 100C


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After Gilling the slivers are taken for post Gilling /top forming machine. Here the top gets desire wt.and be prepared for further process.

Second from polyester

Polyester tow is purchased from Reliance and Germany. Bell wt.appr.300 kgs. Length cutting as perrequirement.

For combing the polyester and make it in TOP form there are some processes are as follow:-1) TOW to TOP converter

A TT machine is used to convert the tow in a single step machine. The tow is continuousso it has to be cut according to the length of wool fibers. The polyester is slant-cut with arotating blade mounted on a drum.

2) Gilling

This process is performed to parallelize the fibers. After this it is converted in to top andsend to the dyeing and spinning department.


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Dyeing department

Wool tops and polyester tops are dyed separately. There are 10 dyeing machines. Each machinehaving 3 cells and each cell having 3 tops and weight of each top is 7 kg.

30% compressing for press the material. 41 C is given to machine for complete dye. Material dyeingis done in three forms:

Top dyeing

Yarn dying

Fabric dying

Some important point for dyeing

Wool is dyed at 100 C Polyester is dyed at 130 C Yarn is dyed at 120 C Light and medium shades are dyed for 30 minutes Dark shades are dyed for 45 minutes 100% wool can be dyed in the form of top or piece dyeing 100% polyester can be dyed either in top or piece. Polyester wool blend can be dyed in piece form only.

After dyeing the top, yarn and fabric they test the matching shade or color according to the customerorder if any color mismatched with the real one they again dyeing the raw materials and after allthese processes there is one another machine is called defelting machine. This machine is basicallyGilling the top because the dyeing tops are slivered after the dyeing.


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RECOMBING DEPARTMENT

During the dyeing process, certain degree of disturbance takes place, so removal of that disturbance

is required. For that re-combing process is required.

Objective of re combing1. to remove short fiber2. to remove dirt and naps3. to strengthen the fiber and make it parallel4. to enhance blending

Process of re-combing

Radio frequency (light shades)

Defelting

Gilling 4 times

Hydro extractor

Back wash (dark shades)

Comber

Gilling 2 times

Auto leveler

Top ready for spinning


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SPINNING DEPARTMENT

Raw for spinning is top which is final product of re-combing. Spinning applies draft to roving, thenapply twist to bind the fiber together to make yarn.

Process of spinning

Rubbing

Ring frame

Gilling 4 times

Single yarn steaming

Single yarn winding

Assembly winding

Twisting on TFO

Double yarn winding

Visual checking

Deliver to store

Roving

Double yarn steaming


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1) Gilling

Objective of Gilling

1. To make the fiber parallel by drafting,

2. To make the sliver even by evenization doubling

There are two sets of gill boxes1) GN-52) GN-6

1set = 4gillboxesNamely,

a, unicoiler with bollfiding

b, uni coiler with auto levelerc, bi coilerd, tri coiler

2) Roving

Objective of roving

1. To reduce the wrapping2. To make suitable package

Roving process include four machines, three machines for flyer frame and one for rubbing.Rubbing is end product for spinning preparatory.

3) Ring frameThere are 27 spinning machines. Spinning include ring frame. Operation of ring frame isdrafting and twisting. Ring frame include,

a) spindle capacity of ring frame400b) total spindle capacity of shed14800c) speed of the machine70009000 r.p.m

4) Single yarn steaming

Objective of single yarn steaming

1. To remove snarling effect from yarn2. To set yarn twist

5) single yarn winding


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Objective of single yarn winding

1. To remove fault from yarn2. To kept appropriate size of packets

This process is done by Autoconer machine. There are 5 Autoconer machines.

6) Double yarn steaming

Steaming is done to fix the yarn from doubling. It makes strong yarn. Here, 2 machines fordouble yarn steaming.

7) Double yarn winding (rewinding)

This is final process. There are two re-winding machines.

8) Assembly winding

Objective of assembly winding

3. To combine two single yarn to make one yarn

9) Twisting on TFO

Objective of TFO

Is to twist two yarn make one in such a way it looked like a single yarn. Process has two steps

1. S twisting with Z2. Z twisting with S

There are 20 TFO machines


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Weaving department

The function of weaving is to convert yarn into fabric.

Process of weaving

Yarn comes from spinning department and stored in yarn store, According to requirement theyprovide yarn to weaving department.

Sales department gives order to planning department and planning department gives order toweaving department.

In 1st process warping, in this process yarn will arrange in rank, process will start on drum and drumwill convert into beam.

In 2nd process drawing, beam is converting into loom according to length and design. collect designfrom design & development department In terms of graph. Vertically and horizontally (warp & wept)

design and arrange it accordingly.

Drawing

Winding

Grey inspection

Warping


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FOLDING AND FINISHING DEPARTMENT

Process of folding

The fabric is checked and the defects are flagged according to their type. White flags are put on thefaults which can be removed in the mending department. Red flags are put on the more severe faultswhich can not be removed and the fabric has to be cut from there.

Then the measuring, cutting, stamping and folding of the fabric is done. Fabric is ready for sale.

Final inspection

Stamping

Measuring $ cutting

Folding

Final inspection

Wrapping package


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Design & development department

Design is innovative and creative. Designer must expert to convert creativity into visual form.Designer makes visual communication, and it helps to satisfy the psychological and aesthetic needsof end user.

Sources of design

Direct feedback of customer Market survey International magazines which contains fabric cuttings. Designer intuition and past experience.

Design department makes sample through handloom and show that sample to sales department andfinally send it to production department for the further processing. For selection of domestic design

two conferences has been arranged. For export products have been prepared before one year.

Monitoring of design trends/seasonal needs and constant development work enable DIGJAM torespond rapidly to market demand and buyer needs. Higher standards of inspection at all stages,using the latest test equipment, ensures the near perfect quality and integrity of DIGJAM woolentextile multi terminal computers reinforce production control applicants.


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QUOLITY CONTROL

DIGJAM MILL having international lab for quality control. It has different machinery like:-1. Strength of thread is testing in one machine.

2. Testing the fiber length in average.

3. Microscope machine for testing diameter.

4. Air flow fiber for testing of stitching garment.

5. Fast instrument machine.

6. Drip meter.

7. Rubbing fast Check.

8. Pilling check.

9. checking(cross checking)

DIGJAM has been obtained its ISO 9001 certificate so it is highly conscious about qualityapart from various quality checks after each and every process, the sample items arescientifically rechecked several at the centralized quality control department. To check theraw materials several test are required i.e. yield % test, grease % test, dust and mud % test forthe checking of vegetable items. With the use of microscope, alimeter test is done to verifythe length parameter, average length, oil % test and diameter of wool top. The same processis used to check the quality of re combed top. In this laboratory fastness and moisture is alsochecked. There is an in house checking in yarn stage. Moreover, the strength of yarn andpilling check is also done. There is a steam testing machine to test the shrinkage.


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(QUOLITY IS DIGJAMS LIFE)

QUALITY POLICY

We, as a company are committed to:

Produce wide spectrum of quality fabrics/ products at competitive price to satisfy the need andexpectation of our valued customer. Our goal is to enhance customer satisfaction throughcontinual improvement.

This shall be achieved by:-

1. Implementing quality management system as per ISI/ISO 9001:2008 in the company in

letter and spirit.

2. Setting and reviewing objectives of various functions in the company.

3. Providing necessary training where applicable.

4. Reducing waste and defective % age during various stages of production.

Project Nilesh

Documents

Transcript of Project Nilesh