Industrial visit

Arvind mills

Presented to:
Dr. Ravi Gor

Presented by:
Lochan Aswani Maulik Barot Jaspreet Kaur

Introduction
It is India's largest denim manufacturer apart from being worlds fourth-largest producer and exporter of denim. Today it not only retails its own brands like Flying Machine, Newport and Excalibur but also licensed international brands like Arrow, Lee, Wrangler and Tommy Hilfiger, through its nationwide retail network. Arvind also runs a value retail chain, Megamart, which stocks company brands. Its headquarters is in Ahmedabad, Gujarat, India.

Employs 243 persons per day. Operates 364 days a year. Production- 80 million meters per month. Machines have a utilization of 70% and 30% is the downtime. Production - make to order basis. 0.1% defect rate in the production. Kaizen projects.

OVERVIEW OF MANUFACTURING PROCESS OF JEANS CLOTH

Spinning Ball warping
Rope dyeing Rebeaming Sizing Weaving Looming Finishing (Sarni area)

Packing

DETAILED ANALYSIS OF EACH PROCESS

1. WARPING :1. WARPING :-

1. WARPING :Process parameters Creel capacity Average Cycle Time Speed Capacity / Day Input Output West Point Yarn 444 ends 4 Hours 330 Meter/Minute 2.4 lakh/ Meter Yarn Rope (Ball)

2.DYEING :-

CONTD..
Machine Process parameters Max. speed Average cycle time Capacity / day No. of workers Input Output Morrison Temperature flow 20 to 26 Mtr/Min 20-22 hrs 1.05 lacks meters 13 Ball Can(dyed material)

CONTD
19 tanks:Tank 1 Tank 2,3,4 Tank 5,6 Tank 7 to 12 Tank 13 Tank14 Tank 15 to 19 Pre wetting & sulfur bottoming Hot water washing Not in use& only used for dyeing highly black Indigo dyeing Washing Sulfur dyeing Detergent ,hot water wash & post wash

CONTD
Post Wash Dyeing Process :Cylinders Color matching 54 Up to the 9th row

REBEAMING

CONTD
Machine Average cycle time Speed Capacity Input Output West point SUKER MULLER 1 hr 45 minute 200-250 mtr/mins. 96000 mtrs Dyed rope with joined ends. Beam

SIZING

CONTD
This process is also known as starching. In this process warped beams are combined to complete the total ends required for one width and yarn is coated with a chemical formulation to withstand friction and stresses during weaving. The re-beamed yarn passes through a machine called Suker Muller sow box, at a temperature of about 90 degrees centigrade. The yarn is starched and is then moved into the accumulator where it is dried and ironed to make the yarn hard and sturdy.

WEAVING

CONTD
There are 2 types of looms used in this process : ZAX LOOM SHED 2 AX AIRJET LOOMS. Total 203 looms are operating in this department. The starched threads are now put together on a machine that weaves them at a speed 700 rpm Daily production of weaving department is 1 lakh meters per day Here customization is also done daily variety of 1500 above, denim is produced.

CONTD
Two types are mainly produced Lycra denim Polyester denim Weaving is r=the nosiest department with a noise of 100 to 105 decibels. On every 10 machines 1 weaver is needed. In 1 shift total 100 weavers are needed. After weaving the fabric then is given finishing. And hence the required output is then ready to be dispatched.

THANK YOU