SUMMER INTERNSHIP REPORT

AT

BMD PVT. Ltd

ON

Production Planning and Logistics

Submitted in partial fulfilment of requirement of

MASTER OF BUSINESS ADMINISTRATION (MBA)

Savitribai Phule Pune University

SUBMITTED BY:-

Yash Joshi

Session: 2014-2016

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Content

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Topics Page No.

Acknowledgement 4

Preface 5

Introduction of the company 6-7

Corporate Social Responsibility policy 8-11

Vigil Mechanism and Whistle Blower Policy

12-13

Research and Design 14

Technology 14

Quality 15

CPPC(Centralized Production Planning and Control) Logistics

16-19

Area of production planning 20-23

Products 24Dealing Department of CPPC 25

Production process:-

ATY(Air Texturizing Yarn) Process 26

Yarn Dyeing 27

Warping 28

Knitting 29-30

Weaving 31

Dyeing and Processing 32-34

Lamination 35

Folding 36-37

Conclusion 38

Acknowledgement

First of all I would like to thank the Management of BMD PVT. Ltd. Banswara for giving me opportunity to do my two-month summer internship in their esteemed organization. I am highly obliged to Mr. NarendraSeksaria for granting me opportunity to undertake my training in CPPC (Centralized Production Planning and Control) department.

I express my thanks to all the members of CPPC department under whose able guidance and direction, I was able to gain deep knowledge of the subject and give shape to my project report. Their constant review and excellent suggestions throughout the project work are highly commendable.

My heartfelt thanks to all executives of BMD PVT. LTD. who helped me gain knowledge about the actual working and the processes involved in various departments.

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Preface

The objective of practical training at MBA level is to give the student an experience of real life issues involved in business world. Practical knowledge also helps us to identify how the theories can be applied in business life. In this report I have put in best of my learning about “BMD PVT. LTD.” Analysing their working and performance, and highlight the company's profile together with its customers and competitors.

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Introductionof the Company:-

Business Type:-Manufacturer / Supplier of Automotive fabric

Year Established:-1995

Products supplied and manufactured: - Woven fabric, knitted fabric, decorative furnishing fabric, flame retardant fabric.

BMD is proud to be the largest manufacturer of automotive furnishing fabric in India. BMD’s products are used as fabric for seating’s and door trims for automobiles. Special fabrics manufactured by BMD are also used in aircrafts, ships and auditoriums.A TS 16949 certified company, BMD, constantly driven by “aiming higher” has come a long way from its humble beginnings in 1997 and is the preferred choice for most of the renowned names in the automotive industry.

A part of the LNJ Bhilwara Group, a billion-dollar conglomerate with significant presence in Textiles, Graphite Electrodes and Power generation, BMD draws upon the industrial heritage of the group as it grows from strength to strength.

Its well-equipped manufacturing plant located in Banswara, Rajasthan, spread over 1, 86,000 sq. meters, produces 8.5 million meters of fabrics per annum.The company manufactures Air Texturized yarns on imported machines from SSM (Switzerland). Yarn and fabric dyeing is done using world class equipment from Thies (Germany).

The weaving section is equipped with state-of-the-art machinery including sectional warping machine from Benninger-(Switzerland), and looms from Dornier- (Germany), Jacquards from Staubli-(Switzerland) and Woven velour Machines from Van de Wiele-(Belgium) among others.

BMD uses advanced warp knitting machines from Karl Mayer, (Germany) for producing flat knit and spacer fabrics & Circular knitting machines from Mayer &Cie, (Germany) &Fukuhara (Japan) for producing circular knit pile, flat and design fabrics.

Perfect embossing is achieved by the advance embossing machines from Dong Won Roll, (Korea) and deep embossing machine from Changzhou Pinghui, China. For variety of finishes, the company has installed state-of-the-art machines from Brueckner (Germany). A series of Flame lamination machines allow BMD to produce high quality laminated fabric by

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attaching foam to polyester fabric. BMD has Production Capacity of 8.5 million meters per annum.

PRODUCTIONPROCESS AT BMD:-

(Sectional/Direct warping)

(Dobby and Jacquard)

(Washing, Shearing, heat setting etc.)

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Purchased yarn

(Finished)

Raw

Material (Yarn) ATY Department

Dyeing Department

Warping Department

Circular Knitting

Sectional Warping

Loom Department

Folding

Processing Department

Folding Department

Grey Fabric

Warp knitting

Direct Warping

Lamination

Folding

Warehouse

Corporate Social Responsibility Policy:-

[Pursuant to Section 135 of the Companies Act, 2013, read with Schedule VII of the Companies Act, 2013 and Companies (Corporate Social Responsibility Policy) Rules, 2014]

Our Vision:-

Investing in the social and economic development of the weaker sections of society around our operations by building a sustainable way of life.

Our CSR Philosophy:-

As, even in the current decade, we continue to see problems like poverty, illiteracy resulting sections of our communities remaining ‘un-included’, we need to address these challenges through suitable efforts and interventions to make a difference to our local communities by ethically supporting them through a combination of volunteer efforts and financial support.

Our CSR Policy:-

Launch our long term education program initiative “VIDYA” to promote literacy &education with special focus on girl children in the age group of 6 to 14 years through introducing teaching programmes which will result in sustained interest of the child in education & learning; Introduction of all programmes by engaging in consultations with local communities to identify needs, obtaining local community’s acceptance or approval of Company’s project and presence through such programmes initiatives in Banswara area.

Our CSR Focus Areas:-

For higher outreach benefitting our rural communities, we would like to focus on programs and collaborate with like-minded voluntary organizations that spark a desire for learning and knowledge through primary education amongst girl children through quality learning tools and programs.

Method of execution:-

We shall implement VIDYA in Banswara area as at least a five year programme so as to see best results of our decision to implement the activity of promoting literacy & education amongst under privileged girl children of the age group 6 to 14 years. Company shall carry out such activity through a registered society or a Section 8 Company under the Companies Act, 2013 (“CSR Partner”). Our choice of CSR Partner shall be a reputed entity having at least 3 years track record in the same focus areas in which the Company intends to carry out its CSR activities and should have complied with the applicable laws and who has not received any notice for non-compliance under any applicable laws from any authorities. The

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CSR Committee shall be empowered to discuss the objectives of the Company with the shortlisted CSR Partner(s) to obtain their schedule of implementation of the programme designed specifically for running VIDYA.

At the end of each financial year, the Company shall procure from the chosen CSR Partner(s) a detailed project report along with pictures, videos and stories on going activity and utilization of the apportioned CSR expenditure during the financial year including amounts utilized including any unspent amounts.

Our Choice of CSR Partner:-

IIMPACT, a reputed independent non-governmental organization and duly registered society who has an established track record of more than 3 years in executing activities in the very aspect which we are committed to implement in Banswara area has been shortlisted as our CSR Partner to support our efforts to promote VIDYA - primary education to benefit under privileged girl children of the age group 6 to 14 years. Company shall collaborate with IIMPACT to deliver the programme by initially setting up 20 Learning Centers in identified villages.

CSR expenditure:-

The allocated budget for implementation of VIDYA in Banswara area shall only be utilized for the benefit of the beneficiaries i.e. the under privileged girl children of the age group 6 to 14 years participating in the programme at each of the established Learning Centres.

For the financial year 2014-15, due to the time taken to identify IMPACT as our CSR Partner and commence implementation of VIDYA, it is anticipated that the entire allocated amounts for this financial year may not be fully utilized and will therefore the allocated but unutilized amounts shall be included into the CSR corpus for implementation of VIDYA in the next financial year.

Schedule of implementation of VIDYA:-

CSR Partner IIMPACT shall provide a detailed Road Map setting out the course of action that they shall undertake to implement the programme at each of the Learning Centres. Any deviation from the set process shall require intimation to and approval of the CSR Committee. The CSR Committee will receive regular progress reports.

Our Goals:-

To ensure compliance with our CSR Policy we shall –

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Comply with the laws of our country

We shall pursue our CSR programs for the benefit & welfare of under privileged persons in our local communities at Banswara.

Ensure that all our stakeholders are aware of our commitment to the cause; engage in dialogue with them to share knowledge and towards building of trust.

Maintain high ethical standards throughout all interactions with local communities.

Manage our CSR programs / projects such that we keep to our agreed schedules

Regularly monitor all our activities and dissemination of information transparently.

The Corpus for any given relevant year would be 2% of the average Net Profits over the last three years, any income arising there from and surplus (if any) arising of CSR activities of our Company. We will commit all the necessary resources required to meeting the goals of Corporate Social Responsibility and any surplus arising out of the non-utilization of the Corpus ear-marked for any relevant year will not be part of business profits of our Company.

CSR Committee:-

The constituted committee shall oversee the activities of the CSR Partner and be responsible for the implementation of the agreed programme and monitoring the utilization of the allocated budget for each CSR activity(s).

The constituted committee shall meet as and when required. Meeting may be convened at such time, place and day as the members of the CSR Committee deem fit. Provisions relating to conduct of Board meetings via video conferencing shall apply mutatis mutandis to meetings of the CSR Committee. The minutes recording the proceedings of the Committee shall be placed before the next Board meeting of the Company for approval.

If required, the Committee may invite experts from various fields to attend its meetings from time to time.

In addition to formulating and recommending the CSR Policy to the Board, the Committee may recommend any amendments from time to time based on identification of any other or further projects considered necessary and implementable by the Company in its local communities.

The Committee shall produce an annual CSR Report containing details of expenditure along with a report on amounts allocated, amount utilized, amount unspent (if any)

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and additional funds required (if any) and expenditure incurred.

Generally ensure compliances (contractual and statutory) in implantation of the Company’s CSR Policy; where considered necessary nominate a team of persons from amongst the employees of the Company and/or third party professionals to co-ordinate the matters entrusted under the CSR Policy.

Vigil Mechanism and Whistle Blower Policy:-

Policy Objective:-

BMD Private Limited (the “Company”) is committed to pursue its business objectives in a fair and transparent manner by adopting highest standards of professionalism, honesty, integrity and ethical behavior and for the purpose encourage and protect any Whistleblower (as hereinafter defined in Para 2.0) including any of its employees who wish to raise and report their genuine concerns about any unethical behavior, actual or suspected fraud or violation of Company’s Certified standing order ( as defined in Para 2.0(a).

Section 177 (9) and (10) of the Companies Act, 2013 (“Act”) read with Rule 7 of the Companies (Meeting of Board and its Power ) Rules, 2014 stipulates that the following class or classes of companies to establish a vigil mechanism for its directors and employees to report genuine concern or grievances:

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a) The companies which accepts deposits from the public

b) The companies which have borrowed money from banks and public financial institutions in excess of Rs. Fifty Crore.

Section 177 of the Act further stipulates that the details of establishment of suchmechanism shall be disclosed by the Company on its website, if any, and in the Board’s report.

In compliance with the aforementioned statutory requirement as provided, the Company has established a vigil mechanism and formulated this policy in order to provide a framework for responsible and secure whistle blowing in order to establish a vigil mechanism to receive, review, investigate into, initiate corrective action, and report on any genuine concern reported by any employee or a director to the Company and also to provide for adequate safeguards against victimization of such persons who avail of this mechanism and to encourage responsible and secure whistle blowing.

This Policy shall in no manner, release an employee from his contractual obligations of confidentiality under the terms of his employment under neither the Company nor the mechanism provided herein shall be used to seek redressal of his personal grievances.

This Policy shall be called BMD Private Limited - Whistle Blower Policy, 2014 and shall come into effect from the date of its notification by the Company, and will remain in force until further orders.

The Board of Directors may at their sole discretion modify this Policy at any time.

Constitution of the Committee:-

The Committee shall be formed by the Chairperson in consultation with the Board of Directors in order to initiate inquiries and undertake investigation into the Protected Disclosures made by a Whistle Blower to the Nodal Officer in accordance with this Policy. The Committeewill generally comprise of three members one of whom will be the Nodal Officer who will act as the Convener. The Committee may co-opt other members including outside experts as the investigation may warrant on a case to case basis.

Documentation of Complaints, Reports and Registers:-

The Company shall maintain documentation of all Complaints or reports including the Registers pursuant to Rule 4.2 subject to this Policy.

The documentation shall include any written submissions provided by the Whistle Blower, any other Company documents identified in the Complaint or by the Company as relevant to the Complaint, a summary of the date and manner in which the Complaint was received by the Company and any response given by the Company

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to the Whistle Blower.

All such documentation shall be retained by the Company for a minimum of eight (8) years from the date of receipt of the complaint.

Reporting:-

The Nodal Officer of the Company shall submit a quarterly report to the Chairperson and the Board of Directors in such form and substance as may be prescribed by the Chairperson regarding action taken on Complaints received by the Company under this Policy. The Vigil Mechanism as established by the Company shall form part of the Board’s report to the shareholders of the Company.

Research and Design:-

BMD's products find application the world over and it always keeps itself abreast of new technology in order to continuously meet global standards.

Participating in international textile exhibitions & fairs, subscribing to the best in designs and trends, nurturing a spirit of research, creativity and development. BMD makes sure that its products are always contemporary and advanced.

The company has a strong in-house design studio and research set up. This section works on leading-edge CAD and CAM systems and software, including Ned Graphics, Corel Draw, Photoshop and other industry standards.

Technology:-

The company manufactures Air Texturized yarns on imported machines from SSM (Switzerland). Yarn and fabric dyeing is done using world class equipment from Thies (Germany).

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The weaving section is equipped with state-of-the-art machinery including sectional warping machine from Benninger-(Switzerland), and looms from Dornier- (Germany), Jacquards fromStaubli-(Switzerland) and Woven velour Machines from Van de Wiele-(Belgium) among others.

BMD uses advanced warp knitting machines from Karl Mayer, (Germany) for producing flat knit and spacer fabrics & Circular knitting machines from Mayer&Cie, (Germany) &Fukuhara (Japan) for producing circular knit pile, flat and design fabrics.

Perfect embossing is achieved by the advance embossing machines from Dong Won Roll, (Korea) and deep embossing machine from Changzhou Pinghui, China. For variety of finishes, the company has installed state-of-the-art machines from Brueckner (Germany). A series of flame lamination machines allow BMD to produce high quality laminated fabric by attaching foam to polyester fabric.

BMD has Production Capacity of 8.5 million meters per annum.

Quality:-

BMD produces fabrics and finished products in millions of meters yet every piece of finished fabric meets its strict quality parameters.

To ensure this, BMD has invested in the right manpower, right processes and technology. The NABL certified, in-house quality testing facility, has equipment like:

Microprocessor controlled tensile strength tester

Tumble pilling tester

Fogging tester

Color Matching- Data Color System

Flammability testing apparatus

Pilling Tester

Abrasion tester

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Stretch and Set Apparatus

Seam fatigue tester

Xenon Arc Weather-Ometer C

Centralized Production Planning and Control and Logistics:-

Company’s Production Planning Department is responsible for making plans for production to meet customer’s requirement. Whenever an order comes it requires a plan to fulfil it. For proper planning, integration and coordination among all departments is must. While converting monthly sales plan into production plan following points are kept in mind by PPC department.

1.Convert metrage from laminated to warped length.

2. Checking of all stages stock and calculating production quantities of in-house Products such as grey/ processed fabric, grey/ dyed yarn and purchase quantities of raw material etc.

3. Machines availability e.g. Loom /Knitting, Yarn dyeing, etc.

4. Balance quantity of last month is not carried over to new month. Check fresh Orders with the plans sent by Marketing.

5. Program to take care that Obsolescence of irregular items is avoided by making specific quantities.

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6. Further to avoid obsolescence of regular items by being careful during time of changeover of quality.

The CPPC Department acts as interface between Marketing and Production departments

On basis of Despatch plan provided by Marketing department, CPPC prepares Production plan and passes on the same to various Production departments and any changes/ revisions are communicated to them as and when received from Marketing. Similarly progress of Production in various qualities is communicated back to Marketing in form of comparison between plans vs. Actuals to keep them updated about the same

Marketing:-

Marketing department has its branches in Noida and Mumbai. They give monthly dispatch targets for different zones covered by each branch to CPPCfor fabric like

Zone OfficeNorth/South Noida

West Mumbai

Major Car manufactures in India:-

� Renault

� Volkswagen

� Skoda

� Honda

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Marketing CPPC Production

� Fiat

� Mahindra

� Toyota

� Nissan

� GM

� Tata

� Ford

� Volvo

� Chevrolet

� Hyundai

� Mitsubishi

� Maruti Suzuki

Customers:-

Automotive Industries-Location of Car Manufacturers:-

OEM (Original Equipment Manufacturer) in automotive industries are car manufactures who have got assembly lines only and manufactures of parts is done by TIER I suppliers.

Zone Place OEM(Original Equipment Manufacturer)

North Gurgaon, Faridabad,Noida

Maruti and Honda

South Bangalore, Chennai Toyota, Nissan, Ford and Hyundai

West Pune, Halol, Nashik and Sanand

Tata, Volkswagen, GM and Mahindra

East Calcutta Hindustan Motors

Tier I: - Seat Maker

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BMD supplies fabric to following seat maker who assemble car seats by adding other part and they supply seats to above car manufacturer.

Zone Name of Seat Makers

North Sharda/SI/HH Interior/Comfort/TS Techsun/NTF

South Dymos/Lear/SI/JCI/TBI/Yangson/Haritta/Varroc

West SI-4/SI/Lear/JCI/SI-3/Raydel/Jai Guru/Ukaya

East Amin

Tier II:-

BMD - Automotive Fabric manufacturer

Logistics:-

BMD Pvt. Ltd. appoints transporters for supplying fabrics to different zone / locations where seat makers are located.

Zone Name of TransporterNorth SAFC, Adinath

South Om Logistic Ltd. Rk Transport

West Punya, Adhinath and RK

East RK

In case of emergency BMD can also transport by Train or by Air.

Daily Dispatch Monitoring by CPPC:-

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Monitoring daily truck IN and OUT

Truck wise daily dispatch information report

Monitoring acknowledgement of fabric Delivery to Automotive companies like Maruti, Hyundai, Honda, and Volkswagen etc.

Daily monitoring of trucks to be deployed for various OEMs and preparing report for qualitywise despatches in each truck

Areas of Production planning:-

In BMD production planning is necessary so that Production Departments can get guidelines on a) what to produce b) when to produce c) How much quantity to produce. These guidelines are provided by CPPC in form of Production Plan.

CPPC department alongwith folding department takes care of preparing Production plans for all Production Departments i.e. ATY, Yarn Dyeing, Grey Fabric Production (Weaving & Knitting), Fabric dyeing & Processing, Lamination.

Production plans are prepared taking care of available facilities and manufacturing processes. It is important to keep in mind maximum utilization of resources and production capacity and in case extra capacity is required it may suitably addressed to Management take a future decision for increasing capacity accordingly.

Grey Fabric Production Planning:-

AS mentioned above, when despatch plan is converted into Production plan, it is actually the plan for manufacture of fabric at Grey Stage. Calculation begins with Dispatch target as per following formula:

Despatch target - Opening stock + Minimum Stock = Production plan (Grey fabric)

Dispatch Target:-

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Monthly targets include orders given by various seat makers for fabrics as per demand of various models of cars to be sold during the month given to them by various car manufacturers. For example, seatmakers of Maruti Suzuki can give order to BMD for 1, 50,000 meter fabric and BMD has to complete the target according to the time.

Minimum Stock:-

CPPC checks the next 3 months projections for each of the approx. 150 qualities and accordingly decides the minimum stock to be kept for each quality, so that there is no shortage or excess production in any of the qualities.

Example of Calculation of Production Plan:-

3 Month Projections is received for June, July and August:-

In June 15 July 15 August 151, 50,000 Meters 1, 60,000 Meters 1, 65,000 Meters

Opening stock is 1, 40,000

Minimum stock is 1, 60,000.

Therefore production plan is

1, 50,000 - 140000 + 160,000= 1, 70,000

It is responsibility of productions departments to timely complete the target.

Yarn Dyeing Plan:-

On basis of fabric production plan, dyed yarn requirements are calculated and dyeing plan is prepared accordingly keeping mind available stocks of dyed yarn and minimum stocks to be maintained for each type of yarn.

Example:-

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Monthly production plan of quality no. 3035B is 10,000meters.

Calculate dyed yarn requirement for above quantity of fabric

If yarn consumption per meter is 200 grams

Then yarn requirement will be 10,000 X 200 / 1000 = 2000 kg

Check out dyed yarn stock as on 1st of month;let’s say opening stock is 500 kg

We will dye 1500 kgyarn and include same in Yarn dyeing plan.

Same working is done in detail for each quality and quantity according to the production plan.

ATY (Air Texturizing Yarn) Production Plan:-

Production Plan for Air texturized yarn is prepared in same way as done above for dyed yarn. It is planned that how much yarn to be produce in which type of quality and quantity.

Requirement of grey air texturised yarn is calculated from Grey fabric production.

Example:-

Total requirement of 400 Dtex yarn is 5000 kg (for all qualities of fabric in which this yarn is used)

Opening stock is 2000Kg

Minimum stock as decided based on next month’s requirement and average consumption;let’s say it is 2500 kg

Then ATY production plan will be 5000 - 2000 + 2500 = 5500 kg

Production plan is prepared for each count suitable as per available spindles. ATY department has 3 texturizing machines consisting of 148 spindles. Taking average count of 700Dtx per day production would be 30Kgs/spindle.

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Processing Plan:-

Production plan for Processing is done on basis of Despatch targets received by folding department from Marketing department. While preparing this plan stocks of processed fabric lying at plant and minimum stocks to be maintained as per future projections are kept in mind i.e.

Despatch plan - Opening stock (Processed fabric) + Minimum Stock (Processed fabric) =Process Plan

Lamination Plan:-

Monthly targets received from marketingdepartment are given in terms of laminated fabrics. As mentioned above, in addition to monthly targets, projections for next 2 months are also provided by marketing department. Accordingly despatch targets are converted into Lamination plan in same way as done for Grey Production plan i.e. Despatch target - Opening stock (Laminated fabric) + Minimum Stock (laminated fabric) = Lamination plan

Here also Minimum stocksare determined as per next 3 months projections for each quality.

Raw material Planning:-

CPPC department calculates the raw material requirements as per fabric production plan, ATY plan, Yarn dyeing plan, Fabric dyeing plan and Lamination plan and sends same to Raw Material department for timely procurement of same

Main raw materials purchased from outside are:

a)Texturised Yarnb) POY Yarn (Partially oriented yarn)

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c) Dyes and Chemicalsd) Foame) Scrim

Functions of RM department:-

A. Planning:- Procurement planning: based on plan received from PPC. Planning is done for Purchase of raw material such as texturised yarn spun yarn, foam, scrim, dyes and chemicals etc. Production planning for air texturised yarn and yarn dyeing. For this, they have to keep eye on Stock available.

B. Physical stock handling of raw material.

C. Inventory management.

D. Vendor follow-up and inward logistic management.

E. Function related to excise.

F. Invoicing of yarn, fabric, store items, wastes etc.

Products:-

Woven Fabrics:-

In the Woven category, BMD offers plain Woven and design Woven products produce on following machines

Plain woven –Dobby

Jacquard-Design

Knitted Fabrics:-

In Knitted Fabrics, it offers Warp Knits and Circular Knit types as follows:-

Warp knit:-

Flat

Pile warp knit

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Spacer

Circular knit:-

Flat Dobby

Flat Jacquard

Pile jacquard

Dealing Departments of CPPC:-

RM (Raw Material)/Excise Duty

ATY (Air Textrisiol)

Weaving

Knitting

Lamination

QC/QMS (Quality Control)

Folding

Dyeing and Processing

Commercial

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IT/ERP (Electric Resourcing Planning)

Engineering

Production Processes:-

ATY (Air Texturizing):-

To increase yarn’s strength it is very necessary to air texturize the yarn before performing any kind of weaving on it. During this process two to six different POYs are wound to each other at a fixed air pressure depending on final count required of air texturised yarn.

Process:-

The first step is to identify the type of polyester yarn to be produced.

The second step is to know the yarn qualitywise requirement which is given by the CPPC (Centralized Production Planning and Control).

After identifying the type the third step is that 2 or more than 2 threads are mix through the water and air pressure on ATY machine.

The fourth step is to produce the quality. (There are 400 to 1800 Dtex; the weight of 10,000m of yarn called Dtex and Denier is the weight of 9,000 meters yarn in grams.)

After preparing the quality the fifth step is to do making package of yarn which is average 2.5 kg weight per roll.

After making a package the last step is that they are put in auto clave chamber

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machine which is 130° temp heated for 50 minute due to this threads are not shrinking while preparing the fabrics.

A/T department has 3 air texturizing machines (TW-2T, DP-2T and Stahle) consisting of 148 spindles. Taking average count of 600 Dtex per day production would be 30Kgs/spindle.

A/T department needs 11 people at a time to function properly, 6 at A/T machine, 1 at Auto Calving, 2 at soft winding and 2 at packing.

Yarn Dyeing:-

Polyester dyeing based on concept HTHP (High temperature High Pressure)

In Yarn dyeing method material is statenesory condition and leguour is rotate.

Yarn dyeing machine

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Raw Material

(POY)

Auto Calving Machine

Soft Winding

PackingDyeing Department

Material

(Yarn Package)

Loading/

Processing

Dyeing

RewindingChamber DryHydro extract

Material Ready for despatches

S.no. Name of Machine Capacity of machine1 YD 1,000KG2 FD 500KG3 SD 185KG4 MD 38KG5 AD 15KG6 BD 15KG7 DD 10KG

Warping:-

In broad words the basic function of this department is to transfer yarn from yarn packages onto beams. There are 2 ways of doing it.

- Sectional Warping Method

- Direct Warping Method

In sectional warping method, the yarn is wound on a drum before finally being wound on beams. Yarn used in sectional warping is mostly air texturisedyarn.These beams are sent to Weaving department.

In direct warping method the yarn is directly wound on to beams. Yarn used in direct warping is mostly texturisedyarn these beams are then sent to Knitting Department.

There are 3 Sectional Warping machines and 3 Direct Warping machines

Process of direct warping:-

Process of sectional warping:-

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Yarn KnittingDirect Warping Machine

Yarn on Beams

A/T Department

A/T Yarn Sectional warping Machine

Yarn

On drum

Knitting:-

Grey fabric is produced in knitting department. Knitting is performed in 2 ways.

- Warp Knitting and

- Circular knitting: In circular knitting warping is not required

Process of warp knitting:-

(From Direct Warping)

-Threading-chain mounting

As required

Process of Circular Knitting:-

v

There are 18 Circular knitting machines (including 7 Pile machines and 11 Flat machines) and 12 Warp knitting machines.

Production of any quality is taken up by Production department as per the specification sheet finalised by Design and Development department. Specifications sheet mainly contains following particulars:

a) Design b) Yarn specs i.e. count, shade, sample no.c) Grey Widthd) Finish width

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Yarn

On Beam

Yarn Warp Knitting Machine

Grey fabric Folding

Yarn FoldingCircular Knitting

Grey fabric

e) No. of endsf) Densitye) Foamf) Scrimg) Dyes and chemicals and their recipes etc

Example of Warp Knitting Production Specification Sheet:-

Preparing a warp knitting production specification sheet which may have important content in it which are as follow

Fabric Quality no .:- (e.g. 4145A, 4149A etc.)

Product Type:-

Flat Pile Spacer

Yarn Type:-

LIM- Low Inter Mingle HIM-High Inter Mingle NIM-No Inter Mingle FDY-Flat Yarn Mono-Mono Filament

Warping Tension:-

At time of beaming the pressure at which yarn is winded on beam is warping tension. It is of different density. E.g. 40 densities

Threading Order:-

The sequence in which yarn is to be winded and mounted of different beam.

Pattern Chain:-

Warping pattern which determines the design.

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Weaving:-

LOOM:-

Yarn beams received from sectional warping is converted into fabric in this department. The loom department has 57weaving machines of maek Donier, Germany. Designs received from designing department are fed in machine through a floppy and machine prepares the fabric according to design. Grey Woven fabric is sent for mendingand thereafter sent for Processing.

Reading of Machine:-

In a weaving department there are 57 machines which produce fabric as per target given by CPPC. Daily noting of production is done by CPPC which includes quantity in meters, Quality Number, Warp Number, and Beam Length which havebeen produced. Machine numbering is done serially with alphabetical series i.e. J for jacquard D for Dobby.

Example of daily reading:-

Jacquard Machine no. 40Quality no. 30322A Production 400 metersEtc.

Dyeing and processing:-

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Fabric

(From

Loom

(Process

Grey

Fabric

Mending

Process LAB:-

Before actual production testing colors, colored yarns etc. done at process lab and for dyeing yarns fabrics we have dyeing dept. It is a computer based lab which operates through software called Smart way/Data color.

There are 3 dyeing machines, one is based on infrared concept which can test maximum 5gms sample second one called multispecies TC is based on concept of PV = NRT (pressure) and it can test 200gms samples. Third one uses glycerin. The lab also has a dispenser to take accurate quantity of colors. At production level yarn is dyed through pressure concept with help of multispecies. Before dyeing yarns the yarn packages are pressed so that a large quantity of yarn can be dyed at once.

Process at dyeing department:-

PROCESSING/FABRIC DYEING:-

This is an important department in terms of adding aesthetic values and finishing the fabric. Washing, shearing setting width of yarn, adjusting length of yarns etc. are some jobs done

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Grey Heat Setting

Folding

Finishing

DryingDyeing

Dyeing Hydro

Rewind

Drying

here. Processing department has 3 different machines for performing these tasks.

1. Scouring Machine -Pacific Jigger, a maker of Harish Enterprise (P) Ltd., IndiaIt requires 2 operators at a time to operate it. It can wash 1500mtr fabric in 3.5 hours.

2. Shearing Machine -Vollenweider (2Pcs.), one is a make of Xetma, Germany and second one is a make of Horgon, Switzerland. This 2 machine set require 4operators at a time and it can shear 3000mtr to 4000mtr fabric (depends upon the quality).

3. Stenter - Make Bruckner, Germany. It requires 4 workers at a time. Its capacity depends upon the required quality.

4. Rope Opener- To open the wash fabrics and it requires 2 workers at a time.

5. VDR and Scanning- Make Rayemenzal - Washing and Drying. Itrequires 4 workers at a

time. Its capacity depends upon the required quality.

During scouring (washing) just water and soap is used to wash the fabric. In shearing, loops of yarn in the fabric are cut by machine. Stenter’s main tasks are to increase strength & stability of fabric, adjusting dimensions of fabric (width, height of yarn etc.) and finishing the fabric. Stenter has 5 chambers in it, it has a batcher also which prepare batches of processed fabric and these batches then transfer to folding department. There are different processes for different kinds of fabrics.

For Woven fabric:-

Fabric

For warp/Circular knitted fabric:-

Fabric

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Grey Scouring

(Washing

Stenter

(Finishing)Folding

No washing is required for knitted fabrics.

For piece dyed fabric:-

Fabric

In all cases the finished fabrics are sent to the folding department.

Piece dyeing of fabric also done here. For this fabric dyeing machine a make of Thies, Germany is used. It can dye 700mtrs to 1000mtrs of fabric in 7 hours (depends upon the fabric being dyed)

Lamination:-

In this department foam and scrim are laminated over the processed fabric. For this a simple process is used, in which the fabric, foam and scrim go into a lamination machine and in the machine with the help of heating process foam gets laminate with fabric on one side and with scrim on other side. LPG gas is used to generate heat in the machine. Proper temperature is key to perfect lamination.

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Grey fabric Vollenweider

(Grey Shearing)

Stenter Folding

Grey Fabric

Folding Stenter

Vollenweider

(Grey Shearing)

Stenter

(Heat Setting)

Dyeing

Process of Lamination:-

There are 2 Lamination machines with installed capacity of 14000 meters each. First Lamination machine is of make Schmitt Macshinen, Germany and it can produce approximately 14000mtrs laminated fabric per day but actual production depends upon requirement and the production plan. At one time 8 operators are required to operate it. Laminated fabric prepared through this process transferred to the folding department.

Folding:-

Fault checking and inspection of fabric at different stages is done here with the help of fabric inspection machines. Folding department has deployed 20 inspection machines (3 post mending),which are made of True Shape, Embee&Shreetex. Two operators are required to operate a machine at a time. Whenever a fault is found they mark it.

There are three steps in folding-

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Foam

Fabric

(From

Scrim

(From Folding)

Central Lamination Machine

Laminated Fabric

Folding

- Grey folding (Before processing also known as Grey Inspection)

- Processed folding (After processing also known as Intermediate Inspection) and

- Laminated folding (After lamination also known as Final Inspection)

Folding department receives grey fabric from knitting/loom department. It is checked on inspection machines and checked fabric goes to processing department. Processed fabric comes back to folding department for inspection before going for lamination. Average length of a batch came from processing would be 200mtrs. Finally the laminated fabric from lamination department comes to the folding department for final inspection.

Scrim (heated) is checked on inspection machines at folding department. Generally if the foam is approved by the QA, it does not require any further checking. Before sending for lamination dust is removed from the fabric with help of Benzene and air pressure.

While inspection permanent faults, holes and cuts are marked in laminated fabric. For marking they use coloured markers, pens, tags/flags etc. If there is only 1/small fault in 1mtr of fabric it will be marked with marker or pen and a tag/flag will be attached at the border of the fabric to indicate the fault. If there are more than 1 fault in 1mtr of fabric it will be cut at 2 places before and after the faults.1 fault in 10mtrs fabric is negotiable but company has to give 20cms fabric as flag allowance on each fault. If there are more than 2 faults in 10mtrs of the fabric it will be treated as waste.

Dispatching the finished product is also a responsibility of folding department. Before dispatching the fabric, its proper packing is very important. The final fabric rolls are packed in bubble sheets before being packed in polythene sheets. It should be taken care of that fabric rolls must be vertical in position at the time of storage and dispatch. Transportation medium company use is road (by trucks), occasionally company uses air and courier in emergency.

Folding Process Flow:-

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Loom (Woven) Warp Knit Circular Knit

Mending

Grey Rolling Grey Rolling

Conclusion:-

The overall conclusion is that Centralised Production Planning & Control Department acts as pivot of overall activities in the plant. It is responsible for complete Supply Chain Management of the Company i.e. coordination with Production departments for timely achieving the Production plan, coordination with Raw Material department for timely procurement, coordination with Folding department for timely despatches, coordination with Marketing Department for keeping track of changes if any in customer requirements for timely revision in production plan wherever necessary for controlling inventory and avoid any shortages/ obsolescence. To facilitate timely despatches and receipt of goods by customers in good shape, it also takes care of complete Logistics Management of the Company.

This also entails coordination with supporting departments like Engineering and PersonnelDepartment for uninterrupted supply of power and labour.

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Transfer to Godown

Issue for Processing

Intermediate Inspection

Processing

Issue for lamination

Final Inspection

Packaging

Dispatch to Customer

Wherever necessary, CPPC escalates matters to Management for their intervention for timely action and corrective measures to be taken by various departments and if required making changes in policy for betterment in Production Planning.

Customer Satisfaction being main goal of the company, CPPC contributes importantly in achieving this goal.

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