elite fabs deva.ms

8/8/2019 Elite Fabs Deva.ms

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1.2 EXPANSION OF THE TEXTILE INDUSTRY

There are three sectors in the textile industry mill sector, and handloom sector. The

latter two are jointly considered under the heading described sector. Over the years, the

government has granted many concessions and incentives to the decentralized sector with the

result that the share of this sector in total production was 76 percent in 1950-51, it feel 38

percent in 1980-81 and further to 3.7 percent in 2001-2002. The share in 1950-51 to 96.3

percent in 2001-02. The share of the entire mill sector was only 1946 million square meters

the rest 40488 million square meters being contributed by the decentralized sector.

The two sub sectors handloom and power looms in the decentralized sector, it is the

power looms sub sector that has grown at a faster pace. For instance, in 2001-2002, the share

of power looms.

In total fabric production was large as 76.8 percent while hand looms contributed 18

percent. There are many reasons for the past development of the power loom sub sector:

i. Governments favorable policies on synthetic fabric industry.ii. Ability of this sub sector to introduce flexibility in the product mix in line with the

market situation;

iii. Low labor costs achieved indirectly through the flexible use of labor itselfresulting in lower cost of production, and providing an edge in the market; and

iv. Increase in exports from the power loom sub sector.

Now they are 13 lakh looms in different regions with concentration in Maharashtra,

Gujarat and parts of Uttar Pradesh. Only lately power looms complexes have been spinning

up in Tamil Nadu and other states. There are about 6.5 million employees working in the

power loom sector. As noted above, hand loom, sub sector now accounts for about 18 percent

total production of fabric. This sub sector provides employment to about 3 million weavers

in households and 12.4 million in complexes or total of 15.4 million.


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With aim of developing the three sectors of the industry via, mills, power looms and

hand loom in an integrated manner; the government announced a new textile policy in June

1985. The main objective of this policy was to enable the industry to increase of cloth of

good quality at the reasonable prices for the vast population of the country as well as for the

export purpose. The textile modernization fund of Rs. 750 crore was created 1986 to meet

the modernization requirements of the industry. A textile worker workers rehabilitation fund

has been set up to provide interim relief to workers rendered unemployment as a consequence

of permanent closure of textile rendered. Another measure of significant importance has

been the deli censing of the textile industry as per the textile order 1993. Under the new

policy prior approval of the government is not necessary to set up textile mills including

power looms.

As a result of all these policy initiatives, the textile industry has been growing steadily

in recent years with the organized sector concentrating mainly on the manufacture of fabrics

for exports and also production if denim or fabrics in great demand in the domestic as well as

overseas markets. The increases in quantities of yarn required by all sectors are being

provided by the spinning mills while many composite mills had also there spinning sections.

Purely spinning mills have been springing up in different states with many large size

units being promoted for catering exclusively to overseas buyers. There has been almost on

Unconscious Division of work amongst the different industry. The organized sector is

concentrating on high quality fabrics intended for exports and also fabric base on systematic

fibers, the power looms sector is growing phenomenally in stature while the hand loom

weavers are turning out products with special designs.


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1.3.3. OUTDATED PLANT AND MACHINERY

Since the cotton textile industry is fairly old in India and number of mills was set up

long back, the machinery and equipment have grown old and outdated and need fast

replacement. Production with the help of such out dated and machinery results in higher

costs and poor quality of product. However, attempts at modernization and replacement of

old machinery by new machinery are hindered on the one hand by the capital/financial

constraints facing many units and on the other hand, by protest from the labour.

Modernization in world automation which is likely to displaces labour. For instance,

according to one estimate, single worker can over see 48 automatic looms. The problem is

aggravated by the fact that due to stagnant demand conditions, there is little possibility of the

displaced labour being employed elsewhere in sector.

1.3.4. LABOUR PROBLEMS

The cotton textile industry has been faced with frequent labour problems. In 1982 the

industry was rocked by a labour strike in Bombay which continued for eight months. While

some problems of labour are genuine it is not do Elite Fabs true that the cotton textile have

become the playground for personal rivalries and the testing ground for some political

groups.

1.3.5. SICKNESS AND RECESSION IN THE MILL SECTION

The textile industry is plagued with the problem of demand recession, financial

crunch, spiraling costs and heavy duty imports. In additional persistent and continued uses of

old plant and machinery has led to low profits and profitability in the mill sector forcing some

of these mills to close down.

1.3.6. COST FACTORS

India is the largest producer of cotton yarn and fourth largest producer of cotton. As

the world demand for cotton yarn is increasing, India is well poised to increase its exports forcotton yarn significantly in years to come. However, much export for cotton yarn

significantly in years to come. However, much will depend on the cost factors i.e. whether

India will be able to complete successfully with China, Pakistan, Taiwan, Brazil, and other

cotton yarn exporting countries as for as cost of production is concerned.


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Compared with China and Pakistan, Indian salaries and wages are higher by 30 to 60

percent making it imperative for Indian mills to maintain a high labour productivity to be

competing. It is also estimated that Indian spinners pay 100-150 percent more than

production cost as against 5-7 percent of the competitions. The cotton cost accounts for

almost 65 percent of cost of production. Therefore it is necessary that mills plan their cotton

purchases at competitive prices.

1.3.7 NATIONAL TEXTILE POLICY, 2002

The national textile policy was announced on November 2, 2002 the basic objectives

of which is to take care of challenges and opportunities presented by the changing global

environment to the domestic textile industry, specially initiation of the process of gradual

phasing out quantitative restrictions on imports and the lowering of tariff levels for

integration of the world textile and clothing markets by end 2004. The strategic thrust areas

identified by the policy are technology up gradation, product diversification, and increase in

exports innovative marketing strategies, financing arrangements, maximizing employment

opportunities and integrated human development.

Among the highlights of the policy are a proposal for setting up of a venture capital

fund for trapping knowledge based entrepreneurs of the industry, extension of the technology

up- gradation fund scheme to all manufacturing segments of the industry and the de-

reservation of the garment sector.


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2.0 COMPANY PROFILE

We introduce ourselves as M/r. Elite Fabs, one of the leading knitwear manufacturer

and exporter from Tirupur, India.

Spread over an area of 55,000 square feet of workspace, backed by the best workforce theindustry can provide and with the vertically integrated setup like Knitting, Dyeing, Printing,

Compacting and Garment Sewing, the company is capable of producing 10,000 pieces of

basic T-shirts, 7000 pieces of Fashion styles and 4000 pieces of Hi-fashion styles per day.

Product range includes basic Jersey Garments to fashion styles such as Reps, Velour,

Fleece, Auto Stripers etc. We are certified forISO 9001:2000 (U.K)

We serve for the major brands in the UK and Europe directly and through importers.

Quality and the nature of the fabric is based on the knitting machines, therefore we

have equipped world renowned knitting machines. The possible fabrics types are Single

Jersey / Pique / Semi jacquard / Interlock / Engineering Strips / Full Jacquard / Wraper Etc.

We use the latest soft flow dyeing machines which maintain a consistent shade

throughout the fabric. We keep production environment clean and hygienic. We use dyes that

are free of ago-dyes, agreeable to the regulations passed against forbidden dyes in Germany.

Shrinkage control or compacting is a mechanical shrinkage control process which is achieved

by the compacting machine imported from TUBE-TEX-USA.

The fabric, cut fabric, semi stitched, fully stitched are embroidered according to

pattern. Be it logo, chest and label, they can be embroidered in the in-house Embroidery

machine imported from Japan.

Cutting Room is handled both manually (for stripes, Jacquards to get the stripes and design

set in side seam) and also mechanically, i.e., Lay cutting of KM cloth by a cutting master to

make consistent and sharp cuts.


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2.1 EXPORT MANAGEMENT

2.1.1 GARMENTS AND ITS IMPORTANCE

In this context, we find that garment industry has become a dynamic growth area inexports, and it will be worthwhile to well a little on its growth and prospects.

The garments industry in India has developed mainly through export efforts. The

exports which were of the order of Rs. 12 crores in 1970-71 have increased to Rs. 4012

crores in 1990-91 and Rs. 8112 crores in 1993 94. Indian garments are being exported to

various parts of the world. Yet our share in the world trade in clothing is less than 2%. To

understanding this phenomenon it would be necessary to comprehend the international setting

in which trade in textiles and clothing takes place.

International trade in textiles and clothing has been regulated since 1974 under the

aegis of the multi rearrangement. An important provision in the MFA is the provision for

regulating exports through bilateral textile pacts between the exporting and importing

countries.

India has bilateral trade agreements with USA, EEC, Austria, Sweden, Norway, Finland and

Canada under the multi fiber arrangement.

The bulk of Indias exports of garments is to the countries with which India has

entered into bilateral agreements under MFA. The Indian readymade garments industry has

much advantage over its counterparts in other countries. It fits neatly into Indian economic

scene, as it consists of a large number of its in the small scale and cottage industries sector.

And is consequently labour intensive providing employment to millions of workers. Its basic

raw material, namely, fabric, comes mostly from the decentralized power loom sector which

in turn sustains a large number of weavers.

In the coming years the garment industry, given the vast labour force in the country

and the country and the cotton edge, can expand its export base.


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2.2 PRODUCTS & FINISHES

A.PRODUCTS

The following are the customers of Elite Fabs.

Charles Vogle Trading AG, Desigual, Super Confex, Western Stores, Tom Tailor, XOXO Jennyfer Bizzbee

It offers the following products

Mens t-shirt/outerwear Ladies t-shirt. outer wear Kids wear Nightwear Mens, Ladies and Kids We are an all round player rather than focusing on single product line. This gives us the flexibility for the future growth.

B. FINISHES

We can do special finishes like

Garment pigment dyed

Different enzyme washes Peaching Tie & dye, Dip dye Brushed Acid Wash


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FABRICS & Printing Range

C. FABRICS

We offer Products in variety of fabric range classified in general as follows:-

Single Jersey Knits Pique Knits Rib Knits single, double, flat back Inter lock Jacquards, Pointal, Stripes Flat Back Rib Two / Three Thread Fleece (Brushed & Non Brushed) French Terry (Brushed & Non Brushed) Lycra Jersey [All feeders] Polar Fleece (Single & Double side) Waffle Knit Cotton/modal and cotton/polyester blends

D. Printing Range

We have a tie-up with printing factory where we can do all type of print

Plastisol prints Foam prints Motif prints Flock prints Pigment prints Transfer prints Discharge Print Reactive Print Gel Print


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2.3 INFRASTRUCTURE - Garments Division

Sl. No Machine Type No. of Machines

1 4 Thread Over Locking Machines 28

2 Twin Needle Flat Locking Machines 13

3 Single Needle Power 32

4 Cutting Machine 2

5 Ironing Tables/Vacum Bed 6

6 Button Stitching Machine 1

7 Stain Removing Machine 2

8 Genset 30 KVA 1


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INFRASTRUCTURE


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2.3.1 INFRASTRUCTURE - Knitting Division

Sl. No Machine Type Make No. of

M/c

1 20&24 Gauge/24

Dia/72 feeder

PAILUNG 1

2 20&24 Gauge/26

Dia/78 feeder

PAILUNG 1

3 20&24 Gauge/30

Dia/90 feeder

PAILUNG 1

4 24&28 Gauge/32

Dia/96 feeder

PAILUNG 1

5 24&28 Gauge/34

Dia/102 feeder

PAILUNG 1

6 20&28 Gauge/24

Dia/44 feeder Auto

Stripe

ORIZIO 1

Production capacity: around 3 tons/day

We can do all type of jerseys, auto stripes, feeder stripes, engineered stripes, Selfdesigns (variations of jersey knit like, pique, French terry etc.,) with and without leas

than.

2.3.2 INFRASTRUCTURE Fabric Processing Division

We have a fabric dyeing facility with a production capacity of 3.5 tons/day. We havemachines with capacity ranging from 1200 kg till 100 kg to have the flexibility of

dyeing big quantities and small quantities as well. In addition to this we have

machines to do 50 kg & 25 kg for sampling purpose.


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We have separate bleaching facility to make white fabrics with the productioncapacity of 2.0 tons/day.

All are imported machines to give good quality fabric

2.4 Collection Ladies

2.5 Collection Men


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2.6 VARIOUS TEAMS OF ELITE FABS

Managing Partners are closely involved in the day-to-day activities and ably supported by the

teams

Merchandising team: Takes care of our Buyers sampling and production. Withregular monitoring and update to our Buyers.

Quality Team: To ensure quality checks are done at every stage to ensure that correctsample is made and production according to our Buyers requirements.

Logistic Team: To take care of our Buyers pre and post shipment importrequirements

Motto of ourTEAM is to DELIGHT Our Customers by achieving the targets consistently

and competently

2.6.1 ROLES & RESPONSIBILITY

MANAGER (E&P)

To monitor negotiation team & administration team performance Shall procure stores material with least price, good quality at better delivery TAT To monitor & control all unit stores stock inventory minimizing non-moving items. Complying with suppliers, excise & commercial provisions. Have to take necessary actions for achieving quality objectives in our organization.

NEGOTIATION TEAM

To procure the required stores & spares keeping in mind of necessary quantity atcompetitive prices in consultation with manager(E&P)

To follow the on time delivery of the material.


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ADMINISTRATION TEAM

To collect indents from units & verify non-moving stock statement received from unitstores

Raise purchase order based on the quotation comparison/list price/order acceptance To raise auto purchase order to procure stores material from confirmed party without

indent, based on stores stock

To ensure compliance with all necessary actions for achieving quality objectives inour organization.

2.7 RAW MATERIAL

The raw materials are essential thing to produce the fabric cloth and the materials

used ultra-white, and various other color products like black, green. The company is being

purchasing these materials from reliance industries ltd.

2.8 MISSION

Will to win in the competitive world by exceeding expectations Achieving the hall mark of success, a platform to attract customers Treating every goal/ target as a challenge Motivation through team work

2.9 VISSION

INNOVATION: striving to be the best through being the first in all services andsolutions

QUALITY SERVICE: always setting a target to exceed expectations CUSTOMER SATISFACTION: Setting a chain reaction of satisfaction in each

customer and creating Reliability.


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3.0 DEPARTMENTS

The following are the various departments present in Elite Fabs.

- FINANCE AND ACCOUNTING-

HR DEPARTMENT- PURCHASE DEPARTMENT- PRODUCTION DEPARTMENT- ADMINISTRATION DEPARTMENT- MARKETING AND SALES DEPARTMENT

3.1 DEPARTMENT OBJECTIVE

To reduce the average lead time from 7 days to 4 days for packing materials by31.12.2010

To enhance the rate of reduction of the non-moving items from 15% to 30% by31.12.2010

To increase purchase of planned items from 60% to 75% by 31.12.2010 To purchase product at 5% lesser than the last three years average price as applicable

during the year 2009-2010

To reduce the delivery time (TAT) to cover 85 items by 31.12.2010 Monitor & measure the customer satisfaction on a quarterly basis & take steps to

fulfill their expectation.

3.2 RECOMMENDATIONS

Some customers are feeling price is very high. Many customers feel offer has to be improved. More awareness must be created among the customers through Advertisements.


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3.3 HR Department

3.3.1 Functions of the HR Department:

Production budget preparation. Fixing the work. Lead of individual workman. Calculation of ideal time and over time stoppage. Recruitment, selection and appointment. Wage and salary administration. Grievance handling. Employment benefits measures. Training and development.

3.4 FINANCE AND ACCOUNTS DAPARTMENT

Finance is the lifeblood of any business organization .It is concerned with allocation

of funds to various areas and Elite Fabs the best mix of financing in relation to the

profitability of the company. Financial System deals with all matters concerned with planning

in term of money.

3.4.1 MAIN OBJECTIVES

The main objectives of the finance and accounts as follows

y To establish the amounts of funds required for achievement of the objective anddetermine the Elite Fabs funds

y To ensure that the profits earned by the company are disposed of the best advantagesof the share holders and company

y To achieve maximum efficiency in the enterprise through proper planning,organization, control of financial resources.

y To achieve and secure safely investmenty To raise and maintain funds at the lowest cost possible


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3.6.1 PRODUCT RANGE:

30s To 100s, 100% cotton yarns in the following varieties. Karded /Combed. Ring Doubled/Two for one twisted Ply yarn(3/4/6) Auto Coned, Auto Leveled. Double hank plain reel/gross reel. Four hank plain reel/gross reel. Yarn conditioned Gassing yarn

3.6.2 TYPES OF PRODUCTION

Elite fab is very flexible in production as it follows the following production

techniques so as to cater to the needs of the customer.

Mass production:

Manufacturing of discrete parts or assemblies using a continuous process are calledmass production. This production system is justified by very large volume of

production.

Flow of materials and components is continuous and without any back tracking.

Make to stock production:

The manufacturer stocks the finished goods in inventory for immediate delivery. This system ensures immediate delivery of good quality, standard products. Elite Fabs follows this system in 30s and in 40s count. Because they are normally in

demand in

The domestic market.


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Make to order:

Elite Fabs Company also follows Make to order production. That is company makeor manufacture products after the receipt of the firm order from the customer.

They opt for receipt for the 70s and 80s count.Layout:

Elite Fabs follows the process layout in its working environment as everything in theProduction is concerned with huge machineries.


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3.6.3 Process of Purchasing Materials

Department Head

Purchasing Requirements

Getting sign from SM

Issuing to Store Keeper

Buying Quotation

Comparison

Choosing the best

Getting approval from SM

Purchasing Materials

Receipt arrival and receiving inspection

If not ok returning the faults

Settlements

Issuing materials to concern Departments


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Fabric Construction

In the weaving process, there is always a fixed relation between the ends, picks and

width of the fabrics with the yarn used in warp and weft. The numbers of warp yarn threads

required in one inch of fabric are called ends/inch and the numbers of weft (filling) yarn in an

inch of fabric are also called picks/inch. This relation indicates the construction of the woven

fabric. The construction having large number of ends and picks is called a heavy construction

and a construction having less number of ends and picks is called light constructed fabric.

The construction of a fabric is described as follows:

For example 20*20/108*58 = 63 1/1, tucked in salvage

Type of Weave

There are three main basic weaves in use for the majority of fabric.

Plain Weave

Twill Weave

Satin Weave

Plain Weave

It is the simplest type of construction. On the loom, the plain weave requires only two

harnesses. Each filling yarn goes alternately under and over the warp yarns across the width

of the fabric. If the yarns are closer together, the plain weave will have higher count.

Twill Weave

A distinct design in the form of diagonals is characteristic of the second basic weave

called the twill. The twill is frequently more tightly woven. Uneven four-shaft twill for

example that has one warp yarn riding over three filling yarns is referred to as three up and

one down, or 3/1. Staple yarn is usually left-hand twill. Wool type fabrics are usually right

hand twills.


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Satin Weave

In basic construction the satin weave is similar to the twill weave but generally uses

from five to as many as twelve harnesses producing a five to twelve-shaft construction. It

differs in appearance from the twill weave, because of diagonal of satin weave is not visible.

Weaving Machines

There are many kinds of weaving machines-looms in use today and the basic

difference in all of them is the technology applied for weft yarn insertion. Following are the

main weaving machine that is used in Elite Fabs

Machines No of Looms

Jacquard Looms (Rs 10,000,000 each) 14

(The machine name is Dornier, These machine have computerize system & make all type of

design and made by German)

Pat Machine 280cm (Rs 500,000 each) 56

(These machine have make a simple design & made by Japan)

Pat Machine 330cm (Rs 500,000 each) 24

(These machine have make a satin design & made by Japan)

Dobby Looms (Rs 6,000,000 each) 24

(The machine name is Zax Navy, these have make a dobby design & made by Japan)

Zax Machine 340cm (Rs 6,000,000 each) 12

(These also make a dobby design and made by Japan)

Zax Machine 280cm (Rs 6,000,000 each) 12

(These also make a dobby design & made by Japan)


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3.7 Total Machine-Looms

Weaving Process

The flow chart shows the basic flow of processes, which is required for weaving.

Warping Sizing

Drawing in Knotting

Weaving Inspection / Grading Folding Packing

Description of Weaving Process Flow

Warping

Warping is the process in which yarn from several hundred cones is wound on abeam. The yarn cones are placed on a rack called creel. From this creel, the yarn are wound

on a warp beam, which is similar to a huge spool. An uninterrupted length of hundreds of

warp yarn results all lying parallel to one another. Different types of looms require different

lengths and density of yarn for the weaving. Normally 650 kg yarn can be wounded on the

beam.

Sizing

The surface of gray yarn is hairy and during the weaving process, yarn is subject to

friction. In order to have better weave, efficiency and less breakage (wastage), the surface of

yarn is to be smoothened and the effects of friction are too minimized. This is done through

the sizing process.


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The purpose of sizing is to apply a protective film to the body of yarn in order to

enable it to withstand the various stress and strains, by which it is subjected to process of

weaving and enhancing its strength and elasticity.

Yarn is coated with maize starch, PVA (poly vinyl acetate) or water-soluble polymers to

prevent it from chafing or breaking during the weaving process.

Calculation of creel beams required for warping 20*20/108*58 = 98 fabric construction

Total ends = (No of ends * Width) + Selvedge ends = (108*98) + 10 selvedge ends =

10,594 ends Creel capacity = 672 (Maximum creel capacity of warping machine)

No of beams required = Total ends / creel capacity = 10,594 / 672 = 15.75 or 16

Beams, so one set for sizing consist of 16 beams i.e.16 beams are to be sized for making one-

warp beams for feeding on the loom.

Drawing in

Purpose of the drawing in process is to prepare yarn for weaving on looms. Ends of

the yarn are passed through the eyes of the healed. The process of drawing warp threads

through healed and reeds is known as drawing.

Knotting

When the yarn on warp beam mounted on the loom comes towards an end, and more

similar variety is to be produced, the yarn from the old beam is knotted with a new beam,

either manually or with the knotting machine mounted on looms, in this case drawing-in does

not have to be performed and time involved in drawing in process is eliminated.

Weaving

The sized and drawn in beam is mounted on the loom at one end and the warp yarns

are conveyed to a cylinder called the cloth roll at the other end, between the eyes of healed

and reed dents. In order to weave fabric, two separate yarns are used i.e. warp yarn and weft

yarn. Warp yarn are generally stronger yarns with more twist per inch and weft yarn are

comparatively softer yarn with lesser twist per inch. In shuttle less weaving, however, this

practice has been eliminated and similar yarns are used for warp and weft to ensure quality

and uniformity of the finished fabric.


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Inspection and Grading

The woven fabric on the beams from the looms is taken to the inspection department

for inspection and grading. The fabric inspected by trained staff on the machines. The fabric

is graded as A B and C, depending on the fabric faults.

There are two fabric grading systems via, Japanese and American. Brief description of

two systems is given below:

Japanese System

In this system, if the total faults per 100 running yards (length and width including),

are up to 80 Points, the fabric is called A grade.

American System

In this system, if the total faults per 100 running yards are up to 25 points, then the

fabric is called A grade,

The points are calculated as follows:

Japanese American

A) One major fault 10 points 4 points

B) Half width fault 5 points 3 points

C) Below half width more than 6 inches 3 points 2 points

D) Below 6 inches width 1 points 1 point

The rejected fabric having minimum piece length of 40 yards or above is called B

grade and if the piece length of the rejected fabric is from 9 to 39 yards, it is called C grade.

If the piece length of fabric is below 9 yards it is called rags. Major cloth faults may be due

to warp or weft yarn poor quality, improper maintenance of loom, poor quality of auxiliary

devices and carelessness on part of weaver.


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3.8 Major Fabric Fault

Warp Marks

Longitude strips along warp may cause missing of one or several warp ends.

Miss picks or set marks

Strips over full and partial width of cloth, improper working of weft fillers, improper

loom stoppage, negligence of weaver.

Difference in warp yarn and weft yarn density

Thick and thin places, improper working of let off motion or fabric takes up motion,

faulty operation of fork, weft filler, improper loom stoppage, etc.

Irregular pick

Variations in weft count, irregular operation of take up and let off motion.

Bad selvedge

Slackening of selvedge ends, improper winding of fabric edges on cloths roll,

improper winding of warp on weavers beam.

Over shoots and fluffing

It is formed by weft yarn, which fails to inter lace with warp and accumulation of fluff

on weft yarn.

Oil stains and dirt on cloth

Careless oiling of looms, dirty hands of weavers, and condition in the shed.


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Major Yarn Fault

Thick and thin yarn

Thick and thin yarn will effect, the warping and sizing. In warping the yarn is

mounted on the warp beams at a certain tension and due to the thin places, the yarn will break

frequently. In sizing, the thin and thick yarn will absorb the sizing material in different

percentages and the sized beams will affect efficiency of looms.

Shade variation and count variation

Yarn prepared from cotton having low staple length will create excessive breakage

during warping and sizing.

Low staple yarn

Yarn prepared from cotton having low staple length will create excessive breakage

during warping and sizing.

Fluffy yarn

Yarn having fluff on it will create harshness on the woven fabric and it will be

difficult to dye

Folding

The inspection department, send the fabric length to folding department in which all

the fabric is folded as per the type of fabric lengths and grades.

Packing

After folding, the fabric is shifted to packing department and the packing department

will pack cloth as per its requirement. For exports the fabric is packed in exports sea worthy

rolls and bales. The bale packing is from 500 yards to 1000 yards or as per buyersrequirement. Some buyers require fabric in roll packing because it is easy for them to put on

the dyeing/finishing machines.


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3.9 PROCESSING DEPARTMENT

The company has continuously invested on hi-technological automated system as well

as modern instruments and equipment. The equipment installed at processing plant has been

sourced from world-renowned manufacturers, thereby enabling Elite Fabs to produce

products conforming to international quality standards. It is strongly anticipated that our

investments will be endless owing to the fact that we are living in an era of dynamic and

unceasing technological innovation currently the processing plant is designed for a

production of 3 million meters of printed and 1.5 million meters of dyed fabrics.

The production of dyed cloth is going to increase to 2 million meters as of January

2005. Printing includes pigment, reactive and vat printing with direct, discharge and resist

methods, and continuous dying on pad-dry-thermo sol and pad-dry-steam. It specializes in

several finishes, e.g. oil and water repellant, anti microbial (anti bacterial, anti static, anti

fungal, anti moth etc.), anti static, up protective, flame retardant, down proof, crease

resistance and wrinkle free, chintz, and special silicone (hydrophobic and hydrophilic).

Woven Gray Fabric Processing

Gray fabrics must be cleaned before they can be put into the finishing process. It

contains sizing material and may also contain oils, other additives and dirt. Complete removal

is necessary in order to finish, dye, and/or print the fabric effectively. The method of cleaning

depends upon the fiber in the fabric, the kind of impurities present, and the construction of

the fabric. Finishing and processing is categorized in several ways. Those concerned with

textile processing may classify them as wet and dry finishes, respectively.

Gray fabric processing and finishing can be categorized into three major classes.

White Bleach

Dyed

Printed

The designers, merchandisers, sales personal, and others are concerned with end product.


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White Bleach

If the cloth is to be finished white or is to be given surface ornamentation, all natural

color must be removed by bleaching. This is also necessary if discoloration stains have

occurred during the previous manufacturing process. Bleaching can be done in the yarn stage

as well as in the constructed fabric.

Dyeing

Dyeing and printing differ in the method by which color is applied to fabric. In the

dyeing process, fiber, yarn, or fabric is impregnated with a dyestuff. To select the proper dye

for a fabric, it is necessary to know which dyes have an affinity for the vegetable, animal, or

manmade fibers.

Printing

In printing, a pattern or a design is generally imprinted on the fabric in one or more

colors by using dyes in paste from or some related means. One form of applying colors

decoration to a fabric after it has otherwise been finished is called printing. There are three

basic approaches to printing a color on a fabric: direct, discharge, and resist.

Woven Fabric Process Flow Chart

The flow chart shows the basic flow of processes, which is required for processing.

Singing and De-sizing

Batching Bleaching Scouring Mercerizing Tendering Dyeing Printing


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Tendering/Finishing

Glazing

Embossing Wash and Wear Finish Calendaring Sunforizing Inspection and Folding

Packing

Description of Woven Fabric Process Flow Singeing and De-sizing In order to

remove the extra fibers from yarn used in cotton or cotton blended fabric weaving, and to

have a smooth finish; singeing is one of the first essential preparatory processes. Singeing is

necessary in order to eliminate the pilling effect on fabric, which may occur due to extra fiber

on the yarn surface. Spun rayon fabrics are also frequently singed. But wool and silk fiber

and would melt resulting in balls on the surface of the fabric. Singeing is accomplished by

passing the gray fabric rapidly over gas flames, usually two burners to a side.

After the cotton cloth leaves the burners, for de-sizing (removing the sizing material),

it is pulled through a solution of an enzyme to digest the starch with which the fabric iscomposed.

Batching

After applying the de-sizing agents, the fabric is rolled on and is constantly rotated,

with polythene cover outside, in order to keep it wet from all sides. This is done to have

chemical reaction of the enzymes with sizing material (for breaking the sizing material). PC

fabric is kept in batching for 4 to 8 hours and the cotton fabric is kept for 8 to 16 hours.


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Bleaching

Bleaching makes the cloth ready for printing. The fabric undergoes three washes. First

two washes are with the boiling water and the third is with a 60-degree hot water. Bleaching

can be done in the yarn stage as well as in the constructed fabric. The kind of chemicals to be

used depends upon the kind of textile fiber of which the fabric is composed.

Scouring

Scouring is a process, in which the fabrics are given special washes to increase their

dye up take. The chemical react with the cellulose of the fabric. In this process the fabric is

passed through chemical of scouring agent and the wetting agent. These chemicals allow the

fiber to swallow and the dye up take will increase. Scouring is done primarily for the fabric

dyeing.

Mercerizing

Mercerizing is an important preparatory process for cotton fabrics. Mercerizing

causes the flat, twisted, ribbon like cotton fiber to swell into a round shape and to contract in

length. The fiber becomes much more lustrous than the original fiber, and its strength is

increased by as much as 20 percent. Its affinity for direct, vat and reactive dyes is much

greater. The processes consist of passing the fabric through a cold 15 to 20 percent solution

of caustic soda. It is then stretched out on a tender frame where hot water sprays remove mostof the caustic. A special washer at the end of the tender removes the balance of the alkali. The

process is continuous.

Tendering

This process is applied at various stages of finishing. Usually a fabric is wet when it is

run into a tender; drying and evening of the fabric width are the primary purposes of

tendering. The tender frame consist of two endless chains carried in rugged rails with clips or

pins, which grip the selvage of the fabric and carry into the heated housing where a blast of

hot air removes any moisture.The tendering process is to keep the warp and weft yarns

straightened and give crease resistance to the fabric. It is an end process for white bleached

fabric. Printed and dyed fabric has to pass through the stander first the bleaching/scouring

and second after printing and dyeing.


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Dyeing

In the dyeing process, fiber, yarn, or fabric is impregnated with a dyestuff. To select

the proper dye for a fiber, it is necessary to know which dyes have an affinity for the

vegetable, animal, or manmade fibers. There are several types of dyeing machines devised for

different kinds of fabric with different kinds of raw material. When a dye colors fabric

directly with one operation of impregnation, without the aid of an affixing agent, the dye is

called direct dye.

Following are the main dyeing methods:

Stock dyeing: The process of dyeing is done in the fiber stage

Yarn dyeing: The process is done after the fiber has been spun into yarn.

Piece dyeing: The dyeing is done on the fabric.

Garment dyeing: It is done after certain kinds of apparel are knitted.

3.10 Export Department

Export department plays a vital role in any organization. Elite fabs export department

is headed by the export manager. The export manager supervises all the marketing and export

activities. Export manager is also responsible for the exploration of local and foreign markets.

He is also making efforts for the development and the progress of the company.

3.10.1 Objectives

To increase the export of the Grey Fabric and Yarn.

To maximize the company profit by increasing exports.

Exploration of the new markets.

Market research making the better information system.

Adopting the new technological a development changes in the field of textile.

To build the image a credibility of the organization.

To earn foreign exchange for the progress of the economy of the country.


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3.10.2Functions

Following are the main functions of the export department.

Export department is responsible for the production planning and the production Follow-up

with the mill.

Customer correspondence as well.

Export department also follow-up the local sale and purchase of the yarn and the

Gray Fabric.

The important function of the export department is to make shipment schedule and the

planning.

Visiting to the existing and new customer.

Providing timely information about the production of the products to the customers which is

also providing a service to its customers and promoting the company image.

Improving the quality of the products with collaboration with the buyer and the production

department.

Bank documents preparation and the follow-up.

Preparing the custom documents.

Dealing with the agents and providing timely information to the parties.

B/L follow-up with the shipping lines.

Export updating system is also the responsibility of department.

Preparing the quality analysis report and sending them to higher authorities.

Maintaining the complete sale and purchase records.

Export department is helping in improving the quality and betterment of the products and

the company.

Providing timely information to the clients is the main service provided by the Elite fabsTextile (Pvt) Ltd export department.


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3.10.3 Export Documentation

Export procedure is a very lengthy process. It involves a number of documents

required by the importer from the exporter. Elite fabs Textile (Pvt) Ltd export department

carefully handle all the steps involve in it. Because a little bit of mistake can cause a great

loss to the exporter and the importer.

Indent

Sales Contract

Letter of Credit

Custom Documents

Packing List

Bill of Lading

Bill of Exchange

Certificate of Origin

Inspection Certificate

Shipping Bill

3.10.4 Custom Documents

The custom documents are very important because it provide the evidence that goods

have been transported and it enables the importer to receive the goods from the custom

authorities. As the order placed by the importer is ready on the due date, the export

department issues the dispatch order to the mill. That the following quality should be

dispatched on the containers specified on this L/C. The goods are loaded on the specified

containers and they are sent to the Karachi port on the specified line. ELITE FABS mostly

does its shipment through the shipping companies.

The shipping lines charge their freight and other charges are paid the agents as well as

for clearance of the goods from the port. The agents handover the documents which involve

packing list and invoices to the shipping lines. As the trailer number, the container number E

form number, quality and the quantity is completely mentioned on this invoices.


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Mode Document Carrier

By sea Bill of lading shipping lines

By Rail Receipt Railway service

By Road way bill Transporter

By Air way bill Air lines

Packing List

Packing list is a document which involves all the complete list of the goods packed in

the particular shipment. It is very important document. It provides a convenience to the

shipping and the clearance authorities.

Features of packing list

It usually shows the marks a number mentioned on the packages.

It shows the weight also.

Each package is marked by a number.

It shows the contents of each package, what is nature, quality and quantity of the

package.

It provides a linkage with the other documents to reference to the invoice number,

date, letter of credit number, and date and vessel name.

Bill of Lading

Bill of lading is one of the most important documents in the whole export documents.

Because without this the importer cannot receive their goods from the destination port.

ELITE FABS first of all drafts the bill of lading and that is sent to the shipping line.

Bill of lading also contains the specifications related to the importer and the exporter. The

name of the exporter, place, the importer, the bank, the quantity is mentioned, the quality is

mentioned, the quality with all specifications required by that, the total value of the goods

which are exported. The date of the bill of lading is mentioned.


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The shipping line and vessel name is given on B/L. Bill of lading is a comprehensive

document that is issued by the shipping line. The date of shipment is also mentioned on that.

Without this the importer cant clear the goods from the destination. ELITE FABS export

department also very quick in follow up of the B/L because they have to transfer the

information to the parties.

Bill of exchange

It is unconditional order in writing, addressed by a person to another, signed by

person giving it, requiring the person to when it is addressed to pay on demand or at a fixed

determinable future date. When the L/C is opened the B/E must be strictly drawn according

to the terms and conditions of the creditor may be drowning on the request of the applicant or

on the bank request through which the credit is opened. B/E is also a important document of

export.

Certificate of Origin

Certificate of origin shows that the good which are being exported are originate from

a country form which importer is allowed. These are required by the authorities in the

importing countries. In order to satisfy and support a claim for the import duty. The

certificate of origin may also be made by the consultants of the importing country in the form

of consoler invoice or legalize the exporters commercial invoice. When explorer called for

L/C, of is with the other documents by reference to the invoice number, L/C number and by

quoting shipping marks and number in order to identify the goods.


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4.0 ADMINISTRATION DEPARTMENT

This is very important department of the organization as the name shows; this

department has to administrate all the operations of the organization. This is handed over to

the A.M (Admin. Manager) of the company who is retired Army officer.

Sections of this department are divided into offices as under:

Labor Office

Security Guard Office

Gate Office

Time Office

4.1 Labor Office

As required by the labor department of the Govt. of Pakistan, this office has been

setup to deal with all the matters that are related with labor. The department is under the labor

officer. He is responsible to resolve all the disputes, conflicts, misunderstanding and any

other kind of matter which may arise from time to time with the labor and the immediate

supervisor or with any other person in the organization. It is the duty of the labor officer to

inform the legal requirements concerning the labor and company affairs as well as any

changes in the labor laws.

It is also the duty of the labor officer to satisfy itself regarding payment of bonus,

gratuity, and the other benefits to labor and to keep their morale and motivational level high.

It is also a requirement to be a successful labor office that he should keep his knowledge up

to date regarding the rules and regulations of the labor department.

4.2 Security Guard Office

The main objective of the security office is to safe handling of the goods from / to themill premises. For the achievement of such objective a team of security guards has been

employed by the company.

All the keys relating the mill office, labor colony, (quarters) are lying into the responsibility

of the security officer.


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No outside visitor can enter in the mills premises without the permission of the Admin

Manager.

Whenever any visitor wants to enter into the mill, security guard firstly contact with the

authority in the mill to grant the permission to enter into the mills premises.

Security guards can check each and every person before coming in or going out of the

company gate for the security purposes.

They see and check the outward going pass of the certain things when these going to out of

the mills premises.

They are the guardians of the everything of the company.

4.3 Gate Office

This office has been made to keep the record of each and every thing coming into and

going out of the mills gate.

For this purpose gate office clerk maintains two types of register called;

1. Outward going pass register

2. Inward going pass register

When everything including raw material, stores supplies, or any other thing comes into the

mills premises a document named as I.G.P is made in which information like date of supplier,

description, quantity of the material and any other remarks are written. In the same way

O.G.P is prepared for outgoing things etc and they made a summery on daily basis and fax to

Head Office.

4.4 Time Office

This office keeps and maintains the time record of all the workers on incoming time cardsand pay register for the final preparation of the workers salaries.

It keeps the attendance records, which is then used to calculate the salary to be paid to the

workers on monthly basis.


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It keeps the records of the over time single as well as double, leaves, number of days

worked of all the workers and then calculate their over time on the basis of the gross salary of

each worker.

It keeps the records of Social Security and Education Cess etc of each employee / worker

payable to government treasury.

It keeps the records of Gratuity, Bonus, Pensions and other benefits including CPL (Cash

Paid Leave) to each employee / worker of the organization.

Core Competencies

The core competencies of the firm includes

Technology

Work Force

Facility

Market Experience

According to management one of the factor, on the basis of which they are competing in the

market is the technology of their product.

The next important thing is the work force according to management; our employees

have been the backbone of the company. They deserve to be given the right condition and

right environment for them to grow and prosper. Throughout the history of the company,

management has prided themselves in its excellent relationship with its employees. This bond

has been recognized as one of the most important ingredient of our recipe for success.

Facility of the firm is also one of the core competencies of the firm. Customer and supplier.

Similarly the market experience is another core competency.


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5.0 MARKETING DEPARTMENT

The companys products are in good demand for the past several years. Hence no

difficulty is anticipated in marketing. The company entered into export market in a humble

way recently. This will be expanded to the best possible extend in future .The entire sales of

the factory are being directly controlled by joint managing director of the company with the

two assistants of junior officers.

They manufacture the yarn based upon the demand and the requirement of order.

They are fully capable to sell what they produced. They gained 5% of Salem yarn market,

10% of Nagari market and 2 % of Coimbatore market. Their share in Indian yarn market is

only 0.61%.

5.1 YARN SALES:

Yarn is manufactured by spinning unit and taking into current total market

requirements, exports order and yarn required for the weaving unit. Accordingly yarn is

manufactured in opened, cut the sophisticated order machines and through ring frames as per

monthly production programmers Chalked out.

5.2 DIRECT SALES:

The sales concluded directly to the buyer from the seller without any mediator. The

company enters into a contract directly with the buyer. The goods must be sent to the buyer

within the stipulated period as per the contract. The contracts have been entered into the

parties as per the terms and delivery of goods and sending of invoices either directly or

through bank will made. Another copy is sent to accounts department. At the time of receipts

of invoices, accounts department debits the parties account and when the cheque is cleared

credit the parties account. If due means periodical follow ups are made.


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5.3 Marketing Mix

Marketing mix is the set of marketing tool that the firm uses to get its marketing

objective in the target market.

4Ps

1. Product

2. Price

3. Place

4. Promotion

Product

The company is committed to produce and achieve excellence in high quality

products. The products range is extensive and includes all sort of curtains, kids bedding,

fashion bedding, traditional bedding, basic bedding and kitchen articles. As a fully integrated

textile manufactures, the companys products range is extensive. It includes various types of

fabrications and blends, such as 100% cotton, cotton lycra, cotton polyester, cotton silk, etc.

The focus is to make differentiated products by using different types of fabrics, such

as solids, dobbies jacquards, etc, and creative styling in the make-up to give high value for

money.

Price

Pricing is an important element in the marketing process for any company. The price

policy of company must be in such a way that it should produce a reasonable profit, for the

company and should satisfy the customer.

Following two factors are very important.

Fixed Cost

Variable Cost


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Fixed Cost

Fixed cost is the cost which remains always same in total whether produce large

quantity or small quantity. Fixed cost per unit rises as the quantity produced decreases and

vice versa. Some companies always try to use their full capacity of production because with

increase in production the fixed cost decrease. Following are some important factors of fixed

cost. Some examples are:

Salaries & wages

Rent

Local Taxes

Fixed cost in value, the cost related to the machinery.

Building cost

Electricity change

Insurance expenses

Plant cost

Variable Cost

Variable cost changes in total with the change in quantity produced. It increases as the

level of activity increases. Per unit variable cost remains same whether to produce large or

small quantity.

Some examples are:

Material Cost

Factory Overhead

Part time Workers

Transportation Charges

Miscellaneous

Fixed cost + Variable cost + Desired profit = Total cost


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5.4 Pricing Objectives

The obvious pricing objectives of Elite Fabs Textile are,

Maximization of profit

To achieve the target return and targeted sales

Maintain the market share

5.5 Pricing Strategies

ELITE FABS adopts following strategies in case of pricing fixing:

Direct Selling

Agent Selling

5.5.1 Direct Selling

If company sells directly then price components will be as follows:

Fixed cost + Variable cost + Desired profit

5.5.2 Agent Selling

If company sells to the customer through agent then fix price in this way:

Fixed cost + Variable cost + desired profit + Middlemans commission

The profit margin depends upon the quality and condition of the market. If the market

will new obviously price level will be low to attract the customer and complete with the

existing competitor.

5.5.3 Pricing Procedure in Local Market

Elite Fabs sells locally only extra quantity left from the foreign order. They call tender

when they want to sell the production in the local market. They sell to those persons whose

tender price will be high. Sometimes, ELITE FABS sells its product itself, when some extra

quantity is left from foreign order, they sell at suitable cost.


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5.5.4 Pricing Procedure for Export

Pricing procedure for export is different from the local procedure they charging the

price in foreign factors before charging the price in foreign market. When any customer

wants to purchase the products, after negotiation they fix the price. Some important factors

are inland freight, sea freight, clearing charges, etc.

5.5.5 Place / Distribution

ELITE FABS exports more than 90 % or its product. So, they are using two types of

distribution channels in export.

Direct Channel

Indirect Channel

5.5.5.1 Direct channel

ELITE FABS is also dealing directly with the customers. As in the local market and

the foreign, the buyers direct contact with the ELITE FABS. So the export departments fulfill

their orders by the transformers. The transporter helps in delivering the products. The

transporters are helping a lot in progressing the textile industry. The comely delivery to the

buyer is the greatest service to the customer, timely delivery is important for the success and

development of the organization.

5.5.5.2 Indirect channel

ELITE FABS to agent & to customer. In the export of textile products, the agents are

the back bone of textile industry. They receive order on the behalf of buyer, give to the seller.

They receive their commission from the buyer and the seller.

The agents also purchase the products; sell them directly to other buyers. So in this trading

they earn enough profit. There have been a large number of agents which are working for their organization in

foreign countries as well as in this country.

Mostly the export business is through these agents. The agents have been successful due to

credibility and honesty of their work.

ELITE FABS mostly receives orders through agents.


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ELITE FABS pays commission to them.

Mainly the responsibilities lie on the agents in case of delayed shipments, payment

problems and the quality problems.

As most of the product of Elite Fabs are exported. So, they use different modes of

transportation to transfer the product from Elite Fabs to customers country.

Mostly Elite Fabs export its products through ship. They are other modes of transportation

also being used

Trucking

Shipping

Air Lines

5.5.6 Promotion

Elite Fabs promotes its products, but to a limited extent.

Elite Fabs provides the company broachers to the buyers.

Elite Fabs provides the samples of the grey fabric. The yarn to the customers.

Elite Fabs has a direct contact with the local and the foreign agents, so they also

promote the company products.

Visits to the customers.

Elite Fabs marketing manager also visits its customers.

Their high quality of the products on the fine count the grey cloth is also promoting

the company and establishing image and goodwill.

Elite Fabs provides the timely information to the customers which help in

promoting. Observation and Suggestions

As the textile industry is in crisis but Elite Fabs Textile Mill limited is performing

very well in such difficult economic conditions. The avenues are always open for further

improvements. I hope that the suggestions given by me that will not only benefit to the

management for getting business but the workers will also efficient in performing their

duties:


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There is centralization of authorities. The Chief Executive and the working Directors take

all the decisions. The authority should be decentralized, because delegation of authority

creates responsibility. If the management will delegate some authority to employees then

employees will feel themselves responsibility and they would work with zeal.

I would like to recommend that management should develop some policies for the

promotion of efficient workers. As there is no any policy for the promotion of the workers, so

it creates unrest among the workers.

There is need for refresher courses for the managerial level employees. If the owners would

make arrangements to provide training to the employees then they would work efficiently. By

doing so the productivity of employees would be improve.

The culture of the organization should be developed as according to the well-established

organization.

The control of the top management should be very strict over the employees so those

employees will take responsibility for their assign job.

Proper training should give to new employees as well as the existing employees for the

improving of their efficiency and productivity.

There is no any procedure for evaluation the performance of employees and hence there are

no extra benefits to the efficient employees. The worker must do work more efficiently when

there would some kind of prize would be given to them, the prize must be as the employees

of the day, month, or years.

There is flat rate of increment for all the employees. This flat rate is also minimal. This is

breading discontent among the employees. The increment should also be given on the basis

of performance and efficiency.

There is lack of staff members in the office, so there is need for the appointments of new

employees to diversify the load of work from the existing employees.


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6.0 SWOT analysis

6.1 STRENGTHS

y Well organized and experienced staff.y Innovative and customer oriented products.y Direct approach to the customer.y Customer satisfaction.y Strong distribution network.y Efficient and fast delivery system.y Good subscription gifts.y

Have separate group for Hindi magazines

6.2 WEAKNESS

y Price of some magazines is high.y They are reluctant in promoting some of their own products.

6.3 OPPORTUNITIES

y It has many products capturing all sectors information so it has an opportunity tobecome a market leader.

y Career 360 is a very good career magazine.

6.4 THREATS

y Existing competitors in the market.y India today has already captured the big market share.


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CONCLUSION

It was really a great opportunity for me to get trained in an organization on the various

aspects of business. This training helped me know that, every company, especially the

garment company has to improve the advertisement and marketing activities as well as the

company has to concentrate on price & offer programmer. The company has to use new

technologies for developing variety of fabric products in industry. It may very useful for

sustain the position in the textile industry.