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Acknowledgement
Expressions are very little to state enormous modest obligations to my loving Parents for their
prayers and strong fortitude to enabling me to accomplish this job.
I take this chance to record my profound sense of appreciation and gratitude to my Internship
Advisor Name, University of Central Punjab for his steady support and inspirational guidance
with his knowledge.
I also am thankful for the affable co-operation from all my concern Managers in the diverse
departments of Business Synergy International for providing me essential information and data
for compilation of my whole Internship.
Executive Summary
Business Synergy International has grown into the foremost business group of Pakistan with
listed firms, concentrating on main business; Textiles. At present, Business Synergy International
is considered to be working locally in provisions of its quality goods and organizational skills.
I recently have done my internship in Business Synergy International, in which I got training
from its diverse departments. The internship on the whole revolved around the product
manufacturing. The structure, the way of working & the dedication of the employees in BSI is
really perfect.
The difference among the achievement & failure is doing tasks right & BSI has always worked
for achievement. apart of all these optimistic points of Business Synergy, I have notice few
places where the enhancement can really boost the efficiency of BSI.
In this report I have given a very concise review of what I have seen throughout my internship. I
also wrote about the Textile business in Pakistan, mission and vision of the company, a
comprehensive SWOT analysis, PEST Analysis and manufacturing process, marketing.
I have made it feasible to write each and every thing that I have learnt. I have all my realistic
efforts in the type of this document which is the asset for my upcoming career.
Industry Profile
The textile industry is the most essential sectors of Pakistan. It adds significantly to
Pakistan’s GDP, employment and exports. It is, in actuality, the backbone of the Pakistani
economy. Pakistan is the 8th largest exporter of textile goods in Asia.
This industry of Pakistan has a total reputable spinning capacity of 1550 million kgs of
yarn, finishing capacity of 4000 million square meters, weaving capacity of 4368 million square
meters of fabric. The industry has a production capacity of 400 million units of knitwear, 670
million units of garments and 53 million kgs of towels.
The industry has a total of 1221 units occupied in ginning and 442 units occupied in
spinning. There are around 20600 power looms in operation in the industry. The industry also
houses around 10 large finishing units and 625 small units. There are approx. 124 large units that
undertake weaving and 425 small units.
Pakistan's textile industry has about 50 large and 2500 small garment manufacturing
units. Moreover, it also houses around 600 knitwear-producing units and 400 towel-producing
units.
According to present figures, the Pakistan textile business contributes more than 60% to
Pakistan’s total exports, which amounts to approx. 5.2 billion US dollars. The industry adds
around 46% to the total output created in the country.
The contribution of this business to the total GDP is 8.5%. It generates employment to
38%, which makes to a figure of 15 million. Though, the ratio of skilled labor is very few as
compared to that of unskilled labor.
The world requirement for textiles is increasing at around 2.5%, due to which there is a
larger opportunity for increase in exports from Pakistan.
Business Synergy International started its business in Pakistan in the year 1986 by
creation of undersized sewing units called Business Synergy International. In the early years
Business Synergy International had to go through a very hard time. It still exists simply due to its
reliability, values, honesty and by business ethics. And for that cause now this firm is in winning
and stable circumstances in the following years. Business Synergy International never misses to
meet prospect challenges. This firm always tries to give its best to attain professional proficiency
and trustworthiness. It all the time tries to give something improved then its customer’s
anticipation. For this cause it’s not only treated as a trusted dealer of readymade attire but also as
a gentle partner toward all its purchasers.
Mission Statement
To provide quality goods and services to our purchasers for their comfort and good return
to the shareholders.
Vision
To be a most victorious company in provisions of quality, goods, finance and services.
Quality Policy
We work mutually as a team for executing and continual upgrading of total quality
structure in order to gain satisfaction of our internal and external customers.
Major competitors
Crescent
Chenab
Arzoo
Amtex
Marketing Strategy
The last year has been hard for the textile business as competition is progressively and
margin of profits is fitting smaller bit by bit. Our competitors in Asia have come up lesser prices
follow-on from lower overhead, cheaper and improved raw resources and equipment.
The marketing section of Business Synergy International issues yard prices for each
contract. They show their goods through internet in the entire world.
Marketing Mix
Marketing mix is the place of marketing tool that the organizations uses to get its
marketing objective in the target market. Figure 1 shows diagram of Marketing Mix in appendix.
It comprises of four P’s which are as follows.
4P’s:
1. Product
2. Price
3. Place
4. Promotion.
1. Product
The organization is committed to manufacture and achieve distinction in high quality
goods. The products variety is extensive and adds jeans and chinos and other garments. It
includes different types of fabrications, such as 100% denim and cotton, cotton silk, cotton
polyester, etc.
The goal is to make differentiated goods by using various types of fabrics and creative
designs in the composition to give high worth for money.
2. Price
Pricing is a significant element in the marketing process for any organization. The pricing
policy of company must be in such a way that it should make a reasonable profit and should
convince the customer. Following two costs are very vital in pricing.
• Fixed Cost
• Variable Cost
Fixed Cost
Fixed cost is the cost which is always same in total whether manufacturing is in large
quantity or little quantity. Fixed cost per unit rises as the amount produced decreases and vice
versa. Some organizations always try to utilize their full capacity of manufacturing because with
boost in production the fixed cost decrease. Some important types of fixed cost are as follows:
• 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 fluctuates in total with alter in quantity manufactured. It increases as the
point of activity increases. Per unit variable cost remains constant whether to manufacture large
or small volume. Some types are:
• Material Cost
• Factory Overhead
Pricing Objectives
BSI’s pricing objective is to achieve the desired return and sales with maximum profits and
also to keep market share high.
Place / Distribution
As market chunk are low so the distribution is direct.
Direct channel
BSI is dealing directly with the buyers. The buyers directly contact to the BSI, as in the
local and the foreign market. So the export section fulfills their commands by the transformers.
The transporter helps in delivering the goods. They also help in progressing the textile industry.
The comely dispatch to the buyer is the best service to the customer, timely delivery is important
for the achievement and development of the firm.
Promotion
• Meeting to the customers.
• BSI provides the organization’s broachers to the purchasers.
• BSI gives the timely data to the customers which help in advertising.
• BSI gives the samples of the grey fabric to the customers.
• BSI has a direct contact with the local and the foreign agents, so they also promote the firm
products.
• BSI marketing manager also meets its customers.
• Their high quality of the goods also promotes the company and builds image and goodwill.
SWOT Analysis
Strengths:
Weaknesses:
Opportunity:
Threats:
Buyer needs demands changes
Changed of government policies
Globally Economic instability
New Entry of competitors
Political instability
PEST Analysis
1. Political Instability:
The political situation of Pakistan is instable. Due to this every government makes their own
new trade policies.
Govt. should implement sustainable policies for the favorable of the exporters as well as the
investors.
2. Economic situation:
The economic situation of Pakistan can also impact the foreign investors rising inflation rate
make the price of production elevated and thus decrease the profit margin of the shareholder.
3. Social situation:
The alter in the lifestyle of the customers affects the rising demand of the BSI products.
The modification in the lifestyle and wants in different demographics also impacts the demand of
the buyers.
4. Technological factor:
Technological progression in all the sectors of Pakistan has changed the whole socio-
economic situation. Particularly in the textile division there is a lot of technological growth.
BSI outstanding computerized equipment and devices are installed in the BSI has made
addition in its recent setup by fitting of well advanced equipment imported from China, Japan
and France.
Departments
1. Grieg fabric store & Inspection
2. Pre-treatment
3. Dyeing
4. Finishing
5. Quality Lab
6. Dyeing Lab
7. Printing
8. Folding
9. PPC
1-GriegFabric:
A fabric that has not been bleached dyed or finished.
Grieg Inspection:
They receive the fabric from Grieg store for its inspection. To check the fabric and do it’s
grading according to the set standards. Here in BSI they inspect 100 % for BSI fabric and 10 %
for commercial customer’s fabric. After completing the inspection they return the fabric back to
Grieg fabric store after grading.
Check weave
Construction
Width
Count
Types of Count
1. Coarse count
3. Fine count
1: Coarse Count:
If count is 1-20 is coarse count
2: Superfine Count:
If count is 21-30 is superfine count
3: Fine Count
If count is 31 and more its fine counts.
Grading of Fabric
They use American Standard for grading which are as follows
A Grade:
A quality which has no fault or less than 15 points per 100 meter is said to be A Grade fabric.
In this quality we can pass the 3 major faults per 100 meter.
B Grade:
A Quality in which fault is continuous till 60 meter is said to be the B grade fabric.
C Grade:
A quality in which fault is 10-36 meters continuous and after 36 meters is fresh mean no fault is
said to be the C Grade Fabric.
CP Grade:
A quality in which fault is 1-90 meters continuous is said to be CP Grade.
Types of Faults:
Starting mark
Double pick
Miss pick
Count variation
Double end
Short end
Rapping mark
Float
Reed mark
Selvedge defect
Wrong drawing
Others
2: Pre-treatment Department.
They receive fabric from Grieg store. They perform following functions
1. Singe – Desize
2. Scour
3. Bleach
4. Solometic bleach
5. Mercerize
Singe:
Singe means to burn superficially. Its means to burn off of loose fiber not firmly bound
into fabric structure. This is the burning of loose fiber from fabric surface.
Desize:
Desize is done in order to remove size from warp yarn. Warp yarn are coated with
sizing agent in order to decrease the yarn breakage in loom in order to improve weaving
productivity. Sizing material can act as resistant towards dyes and chemicals in wet textile
processing. It must be removed in order to doing wet processing.
On a plant they have entry area from here they insert the fabric after this there are brushes
which align the loose fiber or make it visible then after this there is burner who burn the loose
fiber. It has 2 brushes which moves opposite to each other it helps to make loose fiber visible so
that it can burn easily. After this we perform desizing there are compartments. We have tank of
1000 liter we make recipe of this here in tank which pass this recipe in these compartments after
this fabric is roll on batcher. We keep this batcher on rotation for 16 hours.
Bleaching:
Bleaching is a chemical treatment which employed for the removal of natural coloring
matter from substrate. The source of natural color is organic compound with conjugated double
bound. By doing chemical bleaching the discoloration takes place by breaking chromospheres.
Most likely destroying one or more double bound with in this conjugated system the material
appears white after bleach
Natural fibers are off white in color due to color bodies present in the fiber. The degree
of whiteness varies batch to batch bleaching can be define as destruction of these color bodies.
A consistent white base fabric has real value when dyeing it is much easier to reproduce shade
matches on white back ground than other one varies in amount of yellow.
Advantages of bleaching:
Procedure:
After entering the fabric wash it with hot water to wash the fabric and passes it from
the chemical tank to apply chemical on the fabric and the send it to the steam chamber there
fabric stays for 16-18 minutes we do this in order to make chemical react on the fabric so that we
can get our desire result next to this we wash the fabric again to remove the chemical from fabric
next we pass fabric from drums to make the fabric dry and then we roll the fabric on tube.
Mercerizing:
Mercerizing is the process of treatment of cellulosic textile in yarn/fabric form with a
concentrated solution of caustic alkali whereby the fabric swollen the strength and dye affinity of
material increased. When treated in strong solution of caustic cotton fiber swells latterly and
shrinks longitudinally causing important and interesting changes in the properties of fiber / yarn.
Advantages:
Mercerizing Procedure:
Benninger
Morison
Difference between these two plants is on benninger we do not stretch the fabric and it’s
on roll and on maorison we stretch the fabric.
On morison we pass the fabric from caustic tank next pass it from time drail again dip in
the caustic tank again from time drail next to this fabric pass from caustic chain where it stretch
the fabric and suck the caustic from fabric through vacuum after vacuum the fabric pass it from 6
washings next dry the fabric and roll on the batcher.
3- Dyeing Department:
There we have following types of dyeing procedure
1. Vat Dyeing
2. Reactive Dyeing
3. Dispers Dyeing
4. Pigment Dyeing
Thermosol
VAT Dyeing:
Vat dyeing is the finest type of dyeing. It perform 100% on cotton and we perform this
dyeing as follows
Pad dry is a process in which we just apply color on the fabric but we cannot develop it on
thermosol at thermosol we just pad and dry the fabric.
Developing is a process in which we develop the color and we perform it on the pad steam.
Working Of thermosol:
First of all enter the fabric from entry area and the pass it from the tuff in which we
have our recipe then pass it from the padder after padder we pass the fabric from chambers
and out from out area.
Padder pressure:
Through padder pressure we control the LCR of fabric. LCR mean left, right and center of
the fabric
Padder is use to squeeze fabric. If any side is dark we increase the pressure and if any side is
light we decrease the pressure.
Reactive Dyeing:
In this type of dyeing we perform following function
40 if dark shade
45 if light shade
4-Finishing Department:
This is the final department of processing. Basically finishing is a name of sense like
softness or stiffness feel which hand can feel. This department perform stantering , sanforizing
and peaching and calendaring.
Types of Finishing:
1. Chemical Finishing
2. Mechanical Finishing
Chemical Finishing:
In this we use chemicals to give fabric hand feel use chemicals to make fabric soft or stiff
its according to customer demand.
Mechanical Finishing:
In this type we do peaching of fabric it makes fabric hand feel like peach. We also perform
calandering and sanfo in this type of finishing
5 stenter plants
1. Babcock stenter have 6 heating chambers (have clips for stretching)
2. Bruckner stenter have 6 heating chambers (have clips for stretching)
3. Bruckner stenter have 10 heating chambers (have clips for stretching)
4. Monforts stenter have 10 heating chambers (have clips for stretching)
5. Monforts stenter have 9 heating chambers (have pins for stretching)
It work as follows
Fabric enter from enters area then moves towards steam chamber where we give moisture to the
fabric so that we get better shrinkage result next it moves towards sleeve there we give pressure
on the fabric from steam roll then pass the fabric from drums to dry the fabric
Peaching:
1. Micro Peach
2. Light Peach
3. Heavy Peach
Enter the fabric from entry area and then pass it from the brushes (6) which moves clock
and anticlock to each other like 3 forward and 3 reverse then pass through the delivery brush
which clean the fluf from fabric which make by roll it gives fine shape to the fabric then we have
clean brush which also cleans the fluf from fabric
If we want more peach then we need to decrease the speed and increase the fabric tention and
brush speed low and if we want less peach than increase the speed and reduce the fabric tention
if want more peach apply more weight (maximum weight 60kg and minimum weight 5kg)
5-QC LAB
In this department we perform different types of test on fabric to ensure fabric quality and ensure
that quality is exactly what customer asks for. QC lab use two standards to check the fabric (1-
ISO 2-AATCC)
Count
Construction
Composition/blend
Weave
Dye class
Finish
Tegwa
Weight(GSM)
Oil Repellency
Finish width
Seam smoothness
Water repellency
Tensil Strength
Tear Strength
Shrinkage
Skewness
Bowing
Elongation
Growth
Standards:
6-Dyeing Lab:
In this department we make color recipe and check it on the fabric to match it with the
customer given standard. Main function of this department is to match the shade. Marketing
department give standard to the labs in form of swatch or lab dips. So before start the process we
need to check that shade is 100% match with the customer given standard. As we know what’s
the recipe that’s exactly match with the customer given standard we start the process.
1. Red
2. Yellow
3. Blue
Red+Yellow = orange
Yellow+blue = Green
Blue+Red = Violet
Pigment Dye
7-Printing:
They receive fabric from stenter because they required specific width before printing that
is given by the customer. Main function of this department is to print the fabric. They print the
fabric by three ways these are as follows.
Flatbed Printing
Rotary Printing
Digital Printing
Before start printing they required design to which they receive from design studio. Design
studio get the design from marketing department then design studio make this design and send to
engraving department where they develop the screens for rotary printing.
Design Studio:
This department gets the design from marketing department. The design can be on a cd or
can be a fabric if it is fabric they scan it and then make design. After make design they send it to
the engraving department. How they make the design .First they scan then save it on the system
and then count the color start counting color from dark shade and then do the color separation.
Preferable format is tiff for sample on cd.
Engraving Department:
Purpose of this department is to make screens for the rotary. They get design cd from design
studio. They make separate screen for separate colors.
Length of Screen
Screen Mashes
Repeat of screen means that after some centimeters design repeats but the repeat of screen is
640mm that’s maximum that we can print.
640mm
64 centimeters
24.25 inches
Length of screen:
Mashes are holes on screen in per centimeter. Mashes are of following numbers
Screen Rounding:
First we place screen in the oven to make it round because we receive it in flat shape.
Screen Coating:
Next step we coat the screen with the photo emulsion chemical. Photo emulsion is a
coating chemical.
Dry Screen:
After coating we make our screen dry at 50-55 centigrade
CST:
Here we fix the screen
Engraving:
We print the design on the screen
Exposing:
Exposing print on the screen from data given to machine
Developing:
In developing we wash the screen from air and water to open the holes properly. Not a
single hole should be close if it happens then whole design can be waste.
Curing:
We cure the screen by giving heat at 230 centigrade for 45 min
Endring:
After curing we fix the ring at the end of screen. We fix ring at both the ends so that
screen can be fix on the machine
Touching:
In touching we fill the place where color is missing.
This is continuous type of printing in this type of printing we have only 9 colors and
maximum width is 58”.Repeat of 640mm maximum can print.
Fabric enters from entry area and then passes from heating roll it stick the fabric on the
bracket bed then fabric passes from screen after print fabric enters in heating chamber
temperature of chamber is 130 centigrade then fabric comes out from out area.
Digital printing:
In this type of printing there is no limit of colors. This is the latest form of printing. We
save the design in the system and give instruction to the machine. Machine gets the program and
prints the design on the fabric. Here we coat the fabric before start printing on digital machine
purpose of coat the fabric is to increase the fabric pickup and fixing. Digital printing has 1 pass 2
pass and 4 pass.
Black
Blue
Siyan
Yellow
Orange
Magenda
Production:
Reactive Dye:
In reactive dyes after printing we do aging to fix the color for 10 to 15 minutes after aging we
wash the fabric and ready for finish
Pigment Dyes:
In pigment dyes we just cure the fabric after printing. Pigments have polymerize to stick color.
Paste Section:
Reactive paste:
700 kg tank
Water
Pigment Paste:
700 kg tank
Water
Licker ammonia
Binder 3-4%
8-Folding Department:
In this department we perform final inspection of fabric before dispatch it to the customer.
The procedure starts from final inspection then pecking then dispatch to the customer. Their
average daily production is like 20 meters/minute on each machine. 8 hours production is 5000
meters
Final inspection:
They inspect processing and weaving faults at final stage before dispatch to the
customer. Then according to faults they do grading of the fabric. They make headers from end
and start to send it to continuity department.
Processing Faults:
Seem Mark
Clip mark
Stains
Streaks
Selvedge Cut
Over Sanforize
Color Stains
Holes
Dropping Stains
Black Stains
White Spot
Miss Print
Stains
Color Stains
Design out
Color Bleed
White Spot
Black Raggar
White Spot
Printing Streak
Whitness
Machine Stoppage
1. Single Fold.
2. Double Fold.
3. Rolling (Rolls on tube)
Shades Grouping:
Header
Water fall
Depend on customer whatever customer request for they use that mode for shading.
Dispatch:
This department dispatches the fabric to the party for dispatch the fabric they required following
things
Customer Name
Customer Destination
Payment Terms
Payment status
Packing List:
Pecking list contains information regarding fabric grading that how many meters are in A grade,
B grade, cut pieces.
Tolerance Limit:
Tolerance limit standard is +3 or -3 this tolerance is acceptable. Means fabric can be +3 more
than ordered or -3 less than ordered fabric.
They also make dispatch daily report in which they enter day to day dispatch data. This report
contains information that how much fabric is being dispatch to the customer in one day and also
that how much fabric is being dispatched in whole month or till date from start of the month.
This department of planners and merchandisers plans and executes the production
processes and meets delivery schedules. The squad work to improve upon the processes, to
ensure that the flow of information from the marketing department and consumers remains
smooth and in sync with the specified requirements.
This department makes the root plan from receiving to dispatch to the customer. They do
following reports.
In this report they keep data of to date and up to date and total fabric in process. This
report also has average per day production and target production. Also keep data of fabric
receive in greige store
In this report they have status of order that i.e where their fabric is right now and at what
stage it is if someone calls from any department they can inform them from this report about the
fabric status
Issuance Report:
This report keep lab dip status report that dips has been made or send to the customer or at what
stage is dip right now
Conclusion
Business Synergy International is one of the textile groups in Pakistan. The system, the
management style, the policies & decentralized decision making environment is really
remarkable. This document is basically an effort to identify the places which need to be
improved.
In this period of technology, the “Information” is the solution to success in the industry.
This means that the victorious businessman will be who will have the correct information at the
correct time. This statement leads to the conclusion that the Information Sharing Process should
really be improved.
The general analysis is indicating that the organization’s progress has mostly attained
through devotion of employees. The efficiency of its management, their readiness to take benefit
of opportunities and face challenges of changing economic picture, this all adds to the very much
enhanced and sound situation of company. This is considerable for the loyalty and hard work of
all the workers of the firm.
Recommendations
1. At there, bonus is given only to production employees but such incentives should also be
given to other staff members as well.
2. Medical facilities are only given to management staff but such services should also be given
to lower staff.
3. Special training courses should be given to the staff for better output form employees.
4. Transportations facility is given to only management and female staff but not for lower staff.
5. There is also a trouble of work overload on the workers and it should be controled properly
so that the workers are motivated.
6. Overtime should also be given to the employees.
APPENDIX:
References
http://www.lahoreindustry.com/business-synergy-international-co14915
https://www.facebook.com/Business-Synergy-International-335334823170169/