CHAPTER-I

THE SCOPE FOR TEXTILE INDUSTRY IN INDIA:

The importance of Indian textile is well recognized and one of the areas of
strength of this industry is its spinning sector. India has one of the most successful
spinning industries of the world with over 37 million spindles and 500000 rotors.
In cotton yarn, the Indian spinning industry is THE world leader contributing over
25% of world trade.
The origin of textile industry in India dates back to 12th century AD.From
ancient times, India has been an exporter of fine cotton fabrics to all countries of
the civilized world.
The post-independence years saw phenomenal growth of the textile Industry.
To-day not only the textile industry has become more or less self-sufficient in all
respects, whether it be the clothing needs of the growing population, machinery or
raw material but also has gained preeminently of becoming the largest foreign
exchange earner for the country.

The demand and supply position of Hosiery Yarn as in the year 2000 were:
DEMAND SUPPLY PRESENT SIZE END
OF MARKET USERS
IN 000’Tons IN 000’Tons Rs. in Crores
DOMESTIC EXPORTS DOMESTIC EXPORTS
2896 17016 2678 16232 200000 Weavers&
knitters
#values at Rs.100 per Kgs on an average.

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There are about 820 spinning mills in Tamilnadu of which about 296 spinning
mills are in Coimbatore Region itself. In total there are 1561 mills all over India
(Non-SSI). In addition there are 969 SSI units are there all over India.

Source: compendium of textile statistics 2000, Published by the office of the

Textile Commissioner, Bombay

The Textile industry predominant presence in the Indian economy is

manifested by its significant contribution to industrial production,employment
generation and foreign exchange earnings.Currently it accounts for about 4% of
GDP,14% of industrial production and over 30% of export earning of India(3% of
the world garment trade)and has only 7-8% import intensity.About 35 million
people are people are gainfully employed with the industry making it the second
largest employment providing sector after agriculture. To-gather with allied
agriculture sector it provides employment to over 90 million people. The total
turnover of the Indian textile industry is estimated at around Rs.1300 Billion.

As on to-day highly labour intensive textile industries are being closed in

many western countries due to high cost of labour.The western countries prefer to
import for their clothing requirements instead of indigenously manufacturing their
requirements with very high cost.

In addition, India is the only country in the world which produces almost all
varieties of cotton suitable for the manufacture of varied counts of yarn. In the last

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one decade Indian textile industry has modernized its plants in order to meet the
ever-changing varied requirements of world’s clothing needs.

The production of cotton which was just around 70-72 lakhs bales during the
70s and around 101 lakhs bales during mid 80s,hasd now crossed 160 lakhs bale
mark. Government of India has established “The cotton Technology mission” with
a view increase cotton yields as the average yield in the country was the lowest;
only 250 kgs a hector against the world average of 550 kgs a hector. Thus there is
very good scope for doubling our cotton production in the coming years.

The Government of India had signed GATT agreement, which will help
boosting textile exports since the terms under GATT are very much favorable to
India than the multi fiber agreement under which stringent quota systems were
followed. Thus the GATT agreement will increase the textile exports from India
manifold in the years to come.

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INDIA TEXTILE INDUSTRY OVERVIEW

The textile industry (known colloquially in the United Kingdom and Australia as
the rag trade) is a term used for industries primarily concerned with the design or
manufacture of clothing as well as the distribution and use of textiles.

Cotton stage

Prior to the manufacturing processes being mechanized, textiles were

produced in the home, and excess sold for extra money. Most cloth was made from
either wool, cotton, or flax, depending on the era and location. For example, during
the late medieval period, cotton became known as an imported fiber in northern Europe,
without any knowledge of what it came from other than that it was a plant; noting
its similarities to wool, people in the region could only imagine that cotton must be
produced by plant-borne sheep. John Mandeville, writing in 1350, stated as fact the
now-preposterous belief: "There grew there [India] a wonderful tree which bore
tiny lambs on the endes of its branches. These branches were so pliable that they
bent down to allow the lambs to feed when they are hungry." This aspect is
retained in the name for cotton in many European languages, such
as German Baumwolle, which translates as "tree wool". By the end of the 16th
century, cotton was cultivated throughout the warmer regions in Asia and
the Americas. In Roman times, wool, linen and leather clothed the European
population: the cotton of India was a curiosity that only naturalists had heard of,
and silk, imported along the Silk Road from China, was an extravagant luxury. The
use of flax fibre in the manufacturing of cloth in Northern Europe dates back to
Neolithic times.

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Cloth was produced in the home, and the excess woven cloth was sold to
merchants called clothiers who visited the village with their trains of pack-horses.
Some of the cloth was made into clothes for people living in the same area and a
large amount of cloth was exported.

The process of making cloth depends slightly on the fiber being used, but
there are three main steps: preparation of fibers for spinning, spinning,
and weaving or knitting. The preparation of the fibers differs the most depending on
the fiber used. Flax requires retting and dressing, while wool requires carding and
washing. The spinning and weaving processes are very similar between fibers
though.

Spinning evolved from twisting the fibers by hand, to use of a drop spindle, to
a spinning wheel. Spindles or parts of them have been found in very, very old
archaeological sites; they may represent one of the earliest pieces of technology
available to humankind. was invented in India between 500 and 1000 AD[1] It
reached Europe via the Middle East in the European Middle Ages.

Weaving, done on a loom has been around for as long as spinning. There are
some indications that weaving was already known in the Palaeolithic. An indistinct
textile impression has been found at Pavlov, Moravia. Neolithic textiles are well
known from finds in pile dwellings in Switzerland. One extant fragment from
the Neolithic was found in Fayum at a site which dates to about 5000 BCE. There are
many different types of looms, from a simple loom that dates back to the Vikings,
to the standard floor loom.

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History During The Industrial Revolution

The key British industry at the beginning of the 18th century was the
production of textiles made with wool from the large sheep-farming areas in
the Midlands and across the country (created as a result of land-clearance and
enclosure). Handlooms and spinning wheels were the tools of the trade of the weavers in
their cottages, and this was a labour-intensive activity
providing employment throughout Britain, with major centers being the West
Country; Norwich and environs; and the West Riding of Yorkshire. The export trade in
woolen goods accounted for more than a quarter of British exports during most of
the 18th century, doubling between 1701 and 1770 [1]. Exports of
the cotton industry – centered in Lancashire – had grown tenfold during this time, but
still accounted for only a tenth of the value of the woolen trade.

The textile industry grew out of the industrial revolution in the 18th Century
as mass production of clothing became a mainstream industry. Starting with the flying
shuttle in 1733 inventions were made to speed up the textile manufacturing process.
In 1738 Lewis Paul and John Wyatt patented the Roller Spinning machine and the flyer-and-
bobbin system. Lewis Paul invented a carding machine in 1748, and by 1764
the spinning jenny had also been invented. In 1771, Richard Arkwright used waterwheels
to power looms for the production of cotton cloth, his invention becoming known
as the water frame. In 1784, Edmund Cartwright invented the power loom. With the
spinning and weaving process now mechanized, cotton mills cropped up all over the
North West of England, most notably in Manchester and its surrounding towns of
Ashton-Under-Lyne, Stalybridge and Dukinfield.

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 Textile mills originally got their power from water wheels, and thus had to be
situated along a river. With the invention of the steam engine, in the 1760s to 1800s,
mills no longer needed to be along rivers.

Post Industrial Revolution

Many of the cotton mills, like the one in Lowell MA, in the US originally
started with the intention of hiring local farm girls for a few years. The mill job
was designed to give them a bit more money before they went back to the farm
life. With the inflow of cheap labor from Ireland during the potato famine, the
setup changed, as the girls became easily replaceable. Cotton mills were full of the
loud clanking of the looms, as well as lint and cotton fiber. When the mills were
first built, a worker would work anywhere from one to four looms. As the design
for the loom improved so that it stopped itself whenever a thread broke, and
automatically refilled the shuttle, the number of machines a worker could work
increased to up to 50.

Originally, power looms were shuttle-operated but in the early part of the
20th century the faster and more efficient shuttleless loom came into use. Today,
advances in technology have produced a variety of looms designed to maximize
production for specific types of material. The most common of these are air-jet
looms and water-jet looms. Industrial looms can weave at speeds of six rows per
second and faster.

By the later 20th Century, the industry in the developed world had developed a
bad reputation, often involving immigrants in illegal "sweat shops" full of people
working on textile manufacturing and sewing machines being paid less than minimum
wages. This trend has resulted due to attempts to protect existing industries which

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are being challenged by developing countries in South East Asia, the Indian subcontinentand

more recently, Central America. Whilst globalization has seen the manufacturing
outsourced to overseas labor markets, there has been a trend for the areas
historically associated with the trade to shift focus to the more white collar associated
industries of fashion design,fashion modeling and retail.

Areas historically involved heavily in the "rag trade" include London and Milan in
Europe, SoHo district in New York City, the Flinders Laneand Richmond.

In popular culture

 The Rag Trade, a British sitcom

 On est au coton, a controversial 1970 documentary by Denys Arcand attacking
management in Quebec's textile industry.

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1.1 HISTORY OF COMPANY

Vijayaeswari textile mill is located in a fabulous atmosphere pulliyampatti.

The company shared its production during 1982. While communing its production
the company manufacturers only 500kgs of yarn per day. But, presently the
company increased their production capacity to 1300 kgs. In order to cost of
production and to increase quality of the goods the management.

Modernized the machineries and to speed-up administration entire office has

been computerized. The company runs three shifts. First shifts between 6.00 a.m,
and 2.00 p.m. second shift between 2.00 p.m and 10.00 p.m and third shift between
10.00 p.m and 6.00 a.m. for carring are production without any hindrance the
company aim a generator with 110krs capacity.

The main benefit of the modernization already undertook by the company are:

a) machine productivity will increase by at least 1.5 times

b) Quality of yarn manufactured will improve considerably and there by price
Realization is higher
c) Labour productivity will improve reasonably and the same has enabled the
company to reduce its cost of production
d) Electricity consumption per kilogram of yarn produced has come down
owing to better machine productivity
e) Waste production will come down significantly and yarn Realization has
improved thereby cost of raw materials had come down.

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1.2 ORGANISATION CHART

MANAGING DIRECTOR

GENERAL MANAGER

SHIFT INCHARGE

SUPERVISOR

WORKER

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 1.3 OBJECTIVES OF THE COMPANY

(i). To satisfy the customers by offering qualing

(ii). To maintain normal profit
(iii). To increase the sales
(v). To provide employment opportunities to rural
areas.

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1.4 OBJECTIVES OF THE STUDY

The training has been carried out with the following objectives

 To identify the production process and

 To ascertain the functions of various departments

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 CHAPTER – II

PRODUCTION PROCESS

2. PRODUCTION

Prof Stigler says “the production function the name given to relationship
between the rates of input of productive services and the rate of output of
production. Production is considered as an important economic activity.

Production means transformation of physical input into output. For the

production of yarn weather conditions are also should be satisfied. Only when the
conditions is normal the yarn can be produced comfortably when the climate is
very cool or it is of yarn is defected. So it should be normal through the technology
has been developed type defects are been avoided.

Here the physical input is cotton and output produces earn. In order to
produce output input required the inputs are also called factor of production when
it assists in production..

The main purpose of a spinning mill is to convert cotton into yarn .Which can be
used for weaving into clothes that we different varieties of cotton are used to spin
different counts of cotton. The process involved in converting the cotton into yarn
is explained as follows.

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PRODUCTION PROCESS CHART

MIXING

BLOW ROOM

CARDING

DRAWING

SIMPLEX

SPINNING

CONE WINDING

PACKING

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2. 1. MIXING
Different verities of cotton are being mixed here depending upon the
yarn counts proposed to be manufactured and stack mixing is maintained. This is
one of the important process which accounts for the quality and the cost of the
finished goods.

PURPOSE OF MIXING

1. The improve process performance (i.e.) avoiding of capping

2. To reduce and control the cost of production
3. To achieve uniform quality of the products
Then the mixture of cotton& polyester go to another. Process of Blow Room.

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2.2. BLOW ROOM
In the first process different varieties of cotton mixing with fiber polyester
and into the blow room machine .The machined mainly cleans the impurities in the
cotton such as sand, seeds and leaves and gives out in the form of a cap.

The mixed cotton is fed into the blow room MBO and a series of machines
with different types of opening and clearing process will remove heavier impurities
in the blow Room Line. The output of this process are directly routed to carding
machine through chute feed system.

PURPOSE OF BLOW ROOM

1. To reduce the lumps of cotton into small units.

2. To clean the cotton and removes dirt impurities.

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2.3. CARDING

The lap taken from the blow room is fed into the carding machine for further
cleaning and comes out in the form a. Silver, which are stored in a cans .The
process of purification started in blow room process is completed here (After
opening and cleaning, the fibers are converts from known as Silver).

Purpose of Carding
1. T o effect through mixing of fibers.
2. Removal of trash in the lap (or) opens cotton.
3. Conversion of lap (or) opened cotton into silver form.

2.4. DRAWING

This is the fourth process .The silver taken from the carding machines in fed
into the draw frame 8silver at a time and comes out and falls into the can as one
silver. Drawing is a machine that take the wets, though the with is unevenness like
the cotton which is their in one side and opposite to other the drawing machine
take that wets and send the web equally that is known as silver. That silver is
stored in can.In this process the cotton length is reduced and the polish gives in this
section.

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2.5. SIMPLEX

This is the first process where the silver that are got from thedraw frame is
fed in this simplex machine and is thick cotton ropey called roving. In the simplex
machine the silver are taken according to the rotation of bobbin. Then that silver
is stored in bobbin so it is said to be bobbin silver.

2.6. SPINNING

The bobbin silver are taken to the spinning machine take the silver
according to the cots rotation called as yarn. That yarn is rotated in the cots. 15
machines are in the room. First 5 machines are produced 64 counts of yarn.
Another 5 machines 66 courts of yarn again 5 machines 64 counts of yarn one cots
weights becomes 65gms

2.7. CONE WINDING

The earn which are spinned are taken to the cone winding which are
produces by spinning machine are winded a come. The earn is been winded in
come for two types of counts. It can be 66 and 64. 66 types of cones length became
high and weight is low but 64 counts of cone length is low and weight is high.
One cone weight become 1.255 gms the waste are through by the workers.

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2.8. PACKING

One packing consist 40 cones (i.e.) 40 cones weights are 50 Kgs .So they are
packing 40 cones and they are neatly packed to sold. It is easy for transportation.

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 CHAPTER-III
DEPARTMENT FUNCTIONS

3.1. PURCHASE DEPARTMENT

The raw material used for production of yarn is cotton.The raw

materials are purchased from Karnataka Andra Pradesh. At present company has
produced polyester cotton yarn .Raw material for the above producer is (i)
Polyester stabile fiber (ii) Cotton

The raw material Polyester stabile fiber has procedure from mostly at
Reliance industries Ltd Gujarat. Another raw material cotton is procured from
Karnataka Andra Pradesh.

To produce 1250 Kgs of yarn per Day Company requires 1350 kgs (i.e.)
41,000Kgs per month out of the above requirement of raw material of polyester
above requirement of raw material of poly-ester 30,000 Kgs and cotton 11000 Kgs
per month for the raw material requirement to the sources of supply’s
adequate through out the year.

The middle men involved in the purchase of raw material are brakes. They
help to procure the required materials for the produc-tion.Usually, they are paid
commission on the basis of total value of Purchase made.

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 When these raw materials are of part purchase the company includes the
transportatatin charge and when it is in mill delivery the exporter is in charge for
the transportation these raw materials are stored in one particular place. All safety
measures are taken to prevent the raw material from getting damaged.

3.1.1. FUNCTIONS

1. Purchasing of raw materials

2. Issuing the materials to production department on
requisition made by them
3. Maintaining stock of raw material to carry on production
with out any interruption.

3.2. SALES DEPARTMENT

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 The finished product, yarn is directly sold to the buyers. There is no credit
sales .Only cash sales are made by the company to the concerned parties. The yarn
produce are in a Go’s & above 13.170 Per Kg.

The Polyester cotton yarn Produced by the company has been sold at
Bombay IC halkaranji .About the minimum production has sold at Tamil
Nadu.The polyester cotton yarn produced are in good quality and it has been sold
at high demand.

The systematic work performs good efficiency in saves departments in saves

departments of the company.

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3.3. FINANCE DEPARTMENT

All details about expenses incurred by the departments and details about cash.
Position – accounting books, details of loans all ounces etc. are maintained by the
finance department.

3.3.1. FUNCTIONS

1. Maintaining accounts of all the transactions made by the

company.
2. Recording and analyzing cash inflows and outflows of the
Company.
3. Framing the business policy/strategy of the company.
4. Designing the capital structure of the company.

Particulars 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10

Turnover 1366.55 1353.24 1086.31 766.96 538.77 517.06
Net Profit 4.01 14.40 17.19 19.00 17.76 13.77
Cash 11.30 24.98 24.78 25.13 23.00 18.77
Profit
Net Profit 160.49 210.65 301.57 439.03 322.25 422.63
Current 1.91:1 1.37:1 1.36:1 1.38:1 1.53:1 1.40:1
Ratio
TOL/TNW 2.01:1 2.85:1 1.08:1 0.77:1 0.99:1 0.42:1
3.4. STORES

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 Stores play an important place where parts use and when use and when
others are required by the department store incharge will check material received
from the supplies and reject the damaged ones the stores are very important unit of
the company.The purchased products are stored in the stores department cotton is
an company product. This product is produced all period. So it is necessary to
store cotton use in all periods evenly.

The main is having sufficient cotton storage facility inside the mill premises. All
safety measures are taken to prevent the raw materials in store.

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3.5. PERSONNEL DEPARTMENT
Human resource development and management describe wide variety of
activities involved in equipping an organization with staff and this staffing to
watch people and tabs to achieve a high productivity or better services.
Personnel department is considered as the backbone of the organization. In
maintain goods relationship among workers and between the management and the
workers.
The main work is to implement of measure on labour welfare improving working
conditions and pay roll preparation.
The important functions of this department are Recruitment, Selection,
Training, Promotion, Transfer.

Recruitment of workers
The workers are mainly recruited from all areas, the person above 20 year
are eligible for recruitment and on the completion of 60 years, he is revealed of his
duties from the company.

Salary structure
Net salary = basis salary + DA+ convenience allowance.
Deductions = PF(12%) + ESI(1.75)

Leaves granted
There are 9 declared holidays 4 national holidays 5 festival holidays in a
year.

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National holidays
 Republic Days

 May Day

 Independence Day

 Gandhi Jayanthi Day

Festival Holidays
 Pongal

 Tamil New Year

 Ayudha Pooja

 Diwali

 Adipperukku

Timing system
Timing for factory staff 8.30 a.m to 5.00 p.m the working as to workmen is 2
shifts of 8 hours each.
1’st shift: 8.30 a.m to 5.00 p.m (Day shift 12.30 p.m to 1.00 p.m.) intraval.
2’nd shift: 7.00 p.m to 2.00 a.m (Night shift 11.00 to 11.30) interval.
Salary and wages
For staff, salary is given at 2’nd day of every months and for workers
weekly basic of every month.

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Welfare of workers
The company shall provide a safe and healthy working environment and
shall take adequate steps to prevent audients and insuring to health sing in the
course of work by minimizing the cause of halyards inherent in the working
environment is followed.

Grievance handling
Conducting a meeting in every month solves the grievance of workers; it is a
type of goodwill meeting.

Training
The training is given to entire workers.

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QUALITY CONTROL DEPARTMENT

The department undertake a regular inspection in the quality , so as to

remove defect and take alteration action our quality control department is a totally
independent at any time and execute quality audits at our centralized inspection
centre goods are further inspection before packing thus assuring that acceptable
quality level are maintained.
Garment – work man ship, measurement trimming, seam strength shrinkage, and
other aspects as per buyers requirements/ standard per production inspection, line
inspection pre shipment/ final inspection and all other tests, maintains records of
reliable source of supply and price’s of materials.
 Place and follow purchase order.

 Maintain records of all purchase.

 To make sure through inspection that right kind of material has been
purchased.

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WORK STUDY

3.1. FIRST WEEK

During the first week of training profile of the company, stages to be
followed for promoting a company is ascertained.

3.2. SECOND WEEK

Procedure to be followed for placing an order and the places from where
raw materials are purchased has been identified.

3.3. THIRD WEEK

The process to be followed for converting raw materials into a finished

product its ascertained.

3.4. FOURTH WEEK

Various departments in the company and their functions have been

identified.

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CONCLUSION

Vijayeswari textile mill is successfully running more than twenty five years.
The company earns sufficient profit over the years. The company as per their
vision offering qulity goods to their customers at a moderate rule. Further , the
company provides necessary facilities, as required by their workers,
labour turnover . although during the financial crisis,the company is performing
well, which sign of commitment by management workers welfare and satisfying
their customer expectation.