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INTRODUCTION
Spinning is an ancienttextile art in whichplant,animal
orsyntheticfibers are
twisted together to formyarn.For thousands of years, fiber was
spun by hand using simple tools,
thespindle anddistaff.Only in theHigh Middle Ages did
thespinning wheel increase the output
of individual spinners, and mass-production only arose in the
18th century with the beginnings of
theIndustrial Revolution.Hand-spinning remains a
popularhandicraft.
The Spinning is a technological system in which twist is
inserted to the fibers and
yarn is produced. The spinning process includes many processes
which transform the bales of
raw cotton into a yarn ready for weaving. The term "spinning"
can refer to the whole activity or
just to the final process of making the yarn. The raw cotton
arrives in the form of large bales.
These are broken open and a worker feeds the cotton into a
machine called a "breaker" which
gets rid of some of the dirt. The cotton may not be consistent
in quality from bale to bale
therefore samples are taken before getting bales in best
quality.
Natural fiberscotton, flax, silk, and woolrepresent the major
fibers available
to ancient civilizations. The earliest known samples of yarn and
fabric of any kind were found
near Robenhausen, Switzerland, where bundles of flax fibers and
yarns and fragments of plain-
weave linen fabric, were estimated to be about 7,000 years
old.
Cotton has also been cultivated and used to make fabrics for at
least 7,000 years.
It may have existed in Egypt as early as 12,000 B.C. Fragments
of cotton fabrics have beenfound by archeologists in Mexico (from
3500 B.C. )., in India (3000 B.C. ), in Peru (2500 B.C. ),
and in the southwestern United States (500 B.C. ). Cotton did
not achieve commercial
importance in Europe until after the colonization of the New
World. Silk culture remained a
specialty of the Chinese from its beginnings (2600 B.C.) until
the sixth century, when silkworms
were first raised in the Byzantine Empire.
Synthetic fibers did not appear until much later. The first
synthetic, rayon, made
from cotton or wood fibers, was developed in 1891, but not
commercially produced until 1911.
Almost a half a century later, nylon was invented, followed by
the various forms of polyester.
Synthetic fibers reduced the world demand for natural fibers and
expanded applications.
Until about 1300, yarn was spun on the spindle and whorl. A
spindle is a rounded
stick with tapered ends to which the fibers are attached and
twisted; a whorl is a weight attached
to the spindle that acts as a flywheel to keep the spindle
rotating.
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The fibers were pulled by hand from a bundle of carded fibers
tied to a stick
called a distaff. In hand carding, fibers are placed between two
boards covered with leather,
through which protrude fine wire hooks that catch the fibers as
one board is pulled gently across
the other.
The spindle, which hangs from the fibers, twists the fibers as
it rotates downward,
and spins a length of yarn as it pulls away from the fiber
bundle. When the spindle reaches the
floor, the spinner winds the yarn around the spindle to secure
it and then starts the process again.
This is continued until all of the fiber is spun or until the
spindle is full.
The fibers used in the textiles industry as raw material could
be broadly classified
into:
1. natural fibers.
2. Man made fibers.
The natural fibers could be grouped into
a. Vegetable cotton, jute, etc.
b. Animal (Silk and Wool), and,
c. Mineral (Gold, Silver Aluminum etc.)
Man-made fibers could be broadly categorized into:
i. Degenerated, and,
ii. Synthetic Fibers.
Among the degenerated fibers, there protein fivers (cess in,
alginate etc.) and
cellulosic fibers (viscose, poly nosic etc.) the category of the
synthetic man/made/fivers included
polyester, polyamide and acrylic etc.
Cotton is the most widely used textiles fiber today. After the
cotton crop is
harvested the kapas has to be ginned in order to separate fiber
from the seeds. After ginning, the
cotton is available in a loose opened form. For convenience of
handling and transposition, cotton
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is compressed and packed into bales. The quality of cotton is
judge in terms of its Grade and
Staple.
The grading of cotton done with reference to impurities such as
leaves, sand, dust,
broken, seeds naps, moles and color of cotton. But the fiber
properties of cotton are judged
mainly by the length of the fiber i.e. the Staple length.
Quality of cotton depends on its physical
properties viz. length, fitness, strength and maturity by
etc.
India Spinning Industry has gone from strength to strength since
a very long time
now as it was the hub of cotton manufacturing. Cotton is not
only consumed to the highest extent
in India but it has also become one of the most profitable
textiles in the export industry. Spinning
in India can be classified into 2 categories: medium and long
staple. But there was a shortfall in
the 'extra-long' category that continued for many years. There
was a massive downfall in the
cotton spinning in India during 2004-2005. The production rate
of cotton was about 4 lakh bales
that was less by 5 lakh bales from the required rate which was 9
lakh bales. Mr. P. D. Patodia,
the Chairman of the Standing Committee on Cotton, CITI-CDRA said
that the manufacturing of
cotton will rise to 11-12 lakh bales in 2010.
The present downfall in the cotton production has witnessed a
50% increase in the
price of Indian varieties of ELS, which is detrimental for the
spinning industry in India. Spinningmills require domestic
accessibility of ELS cotton in increased quantity and of better
fiber
qualities.
Advantages of Training
There are many advantages in conducting training, They are:
Man Power Development.
High Morale.
Higher Performance.
Uniformity of Procedures and increased
Economy of Materials and Equipment.
Results in less supervision.
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Scope of Training
The trainees learn on the actual equipments in use and in the
true environment
of the job.
The trainees learns rules and regulations, procedures by
observing their day to
day operations in the company.
This type of training can increase knowledge with skill in short
period.
Objectives of the training
To study about the production process. To know about the
organizational structure.
To know about the various department activities.
To improve the personal skills & management skills of the
trainee.
To observe the working methods of KUMAR TEXTILES PRIVATE LTD.,
Industry.
Limitations of the training
A good manager of the organization is not willing to provide the
necessary
support to carry out the training.
In some departments the workers did not share the necessary
information.
The main objective of training is get first-hand knowledge of
the organization
but the trainers are not permitted to take any problem for this
study.
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INDUSTRY PROFILE
The textile industry is a term used for industries primarily
concerned with the
design or manufacture ofclothing as well as the distribution and
use oftextiles. Prior to the
manufacturing processes being mechanized, textiles were produced
in the home, and excess sold
for extra money. Most cloth was made from eithercotton orflax,
depending on the era and
location. By the end of the 16th century, cotton was cultivated
throughout the warmer regions
inAsia and theAmericas. 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 theSilk Road from China, was an extravagant
luxury. The use offlax fibre in the
manufacturing of cloth in Northern Europe dates back to
Neolithic times.
Cloth was produced in the home, and the excess woven cloth was
sold to
merchants calledclothiers 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 forspinning,spinning,
andweaving orknitting.
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The key British industry at the beginning of the 18th century
was the production
oftextiles made withwool from the largesheep-farming areas in
theMidlands and across the
country (created as a result of land-clearance
andenclosure).Handlooms andspinning
wheels were the tools of the trade of theweavers in their
cottages, and this was a labour-
intensive activity providingemployment throughout Britain, with
major centers being the West
Country. The textile industry grew out of theindustrial
revolution in the 18th Century asmass
production of clothing became a mainstream industry. Starting
with theflying shuttle in 1733
inventions was made to speed up the textile manufacturing
process. In 1738Lewis Paul andJohn
Wyattpatented theRoller Spinning machine and theflyer-and-bobbin
system. Textile mills
originally got their power fromwater wheels,and thus had to be
situated along a river. With the
invention of thesteam engine,in the 1760s to 1800s, mills no
longer needed to be along rivers.
By the later 20th Century, the industry in thedeveloped world
had developed a
bad reputation, often involvingimmigrants in illegal "sweat
shops" full of people working
ontextile manufacturing andsewing machinesbeing paid less than
minimum wages. This trend
has resulted due to attempts to protect existing industries
which are being challenged
bydeveloping countries inSouth East Asia, theIndian subcontinent
and more recently,Central
America.
Whilstglobalization 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 morewhite collar associated industries offashion
design,fashion modeling and retail.
India Textile Industry is one of the leading textile industries
in the world. Though
was predominantly unorganized industry even a few years back,
but the scenario started
changing after the economic liberalization of Indian economy in
1991. The opening up of
economy gave the much-needed thrust to the Indian textile
industry, which has now successfully
become one of the largest in the world.
India textile industry largely depends upon the textile
manufacturing and export.
It also plays a major role in the economy of the country. India
earns about 27% of its total
foreign exchange through textile exports. Further, the textile
industry of India also contributes
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nearly 14% of the total industrial production of the country. It
also contributes around 3% to the
GDP of the country. India textile industry is also the largest
in the country in terms of
employment generation. It not only generates jobs in its own
industry, but also opens up scopes
for the other ancillary sectors.
India textile industry currently generates employment to more
than 35 million
people. It is also estimated that, the industry will generate 12
million new jobs by the year 2010.
Indian textile industry can be divided into several segments,
some of which can be listed as
below:
Cotton Textiles
Silk Textiles
Woolen Textiles
Readymade Garments
Hand-crafted Textiles
Jute and Coir
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COMPANY PROFILE
ABOUT KUMAR SPINNING MILLS
Kumar Spinning Mills Private Ltd an ISO 9001:2000 company
started at the year
of 1990, a major yarn producer and manufactures. It is located
at Kappalur, from Madurai. Total
area of industry is 10 acres. Only 30 percent of the area is
utilized for the industry buildings.
In 1990 the Kumar Spinning Mills Private Limited has started
with 3000 spindles.
The main product is Reeling yarn and Cone yarn. In early stage
the yarn produced was used for
bet sheet and towels. The count of yarn spun were 20s, 30s,
2/20s. The turnover was around
rupees 2 crores per annum. The number of labours employed was
70. In 1995 the mill was
expanded the spindles with 3000 and the total spindles was 6000.
The count of yarn spun were
20s, 30s, 40s, and 2/20s. The turnover was around rupees 5
crores per annum. The quality of
yarn was improved from weft to warp. The number of labours
employed was 120.
In the year 2000, the mill was expanded the spindles with 4000
and the total
spindle was 10000. The turnover of the company was around Rs.5
crores per annum. The quality
of yarn was improved from warp to hosiery.
In 2003, the mill has expanded the spindles up to 12000, with
latest machineries
imported from foreign countries. The counts of yarn spun were
20s, 30s, 40s, and 52s. The
turnover of the company was around Rs. 12 crores per annum. The
number of labours employed
was 250. The yarn was supplied to number one brand customer like
SANKU MARKS, 144,
3MANGOES, KIBS, etc.
In the year of 2005 the mill is having 15000 spindles with
latest machineries
from leading machineries manufacturers. And the company gets the
auto cone winding machine,
which gives quality of yarn production.
Now the year of 2010 the company only having 107 ladies and 69
men labours in
industry totally 192 workers are working in the company, because
the power cut the government
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orders to the spinning mills have only running 60 percentages of
machineries and so the
company gives retirement to their employees.
There is three shift production are done in Kumar Spinning Mills
Private Limited.
The shift times are as follows.
o Shift 1working time (7am -3pm)
o Shift 2working time (3pm -11pm)
o Shift 3working time (11pm -7am)
CUSTOMERS
Palani mudaliyar & co.
Sri ram textiles.
Saravana fabrics.
C.S exports.
Dharshini pvt ltd.
COMPETITOR
Sri Gomathi Mills Private Limited
Ganapathy Mills Limited
Subburaj Spinning Mills Private Limited
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ORGANIZATIONAL STRUCTURE
Sales
Executive
Worker
Marketing
manager
Store
KeeperSupervisor Labor
officer
Assistant
Engineer
Worker Worker Worker Worker
Production
manager
Purchase
manager
EngineerHuman
resource
Accountant
Worker
Finance
manage
Board of Directors
General Manager
Quality
assurance
mana er
supervisor
Worker
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PURCHASE DEPARTMENT
Purchase is the most important and necessary department in the
spinning mill. This helps to
get continuous available of raw material to the company. The
purchase of cotton is estimated by
the word bale.
Purchase Procedure
Samples
For the purchase of yarn, which is the main raw material for
producing cloth the company
will procure various samples from various supplier strong their
representative. According to their
quality requirements, they will analyze the sample and finalize
the yarn purchase.
Quotations
For the purchase of machinery, tools, parts, other than cotton
they invite quotation from
various suppliers. After the quotations were received they
analyze the quotations, based on the
price and quality. Finally they will finalize one quotation
which is quoted low in price and of
best quality.
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Payment to Raw Material
The company purchase raw material both by credit purchase and
cash purchase. The
credit purchase will be given a time period 30 or 40 days. The
time period in the case of cash
purchase is maximum four days. The purchase of packaging cones
and cotton are based on theweight and quality of the bags.
Direct Payment
The direct payment is a mode of paying money to the supplier
directly. For the small
items purchased will be made on direct payment. In this type the
organization will pay the
amount immediately and directly with ease, where the amount
involves less money, the direct
payment is preferred.
Purchase of Stationary and Misc things
Usually the materials required by the department enter their
order in computer.
Then orders placed will be shown to the purchase department, the
purchase department then
checks the materials that are available in store and invite
quotations if it is not available in the
store. The quotation which is low and better quality is selected
and order is placed. But this
process is not suitable for small things like stationary like
pen, pencil, paper, etc., and emergency
materials.
Importance of Purchases Department
Purchasing raw material to the factory without which the wheels
of machines
cannot move.
Savings in material cost will increase profits in the
turnover.
Material managements organizations that exist now have evolved
out of
purchasing departments.
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Store Keeper
The purchase- in charge maintains the storage details in the
factory premises. The store
keeper is fully responsible for the material stored in the
stores. He will maintain proper books for
every movement of materials.
Functions of Store Keeping
Receiving handling & speedy issue of materials.
To ensure regular supply of materials.
Effective utilization of store space
To keep the details of the items available in store up to
date.
To provide service to the organization in most economical
way.
Duties of Purchase Manager
To make purchase of reasonable quantity so as to keep investment
at minimum.
To make purchases at economical price.
To purchase the proper quality of raw materials.
Samples are tested by lab assistants about the grade, stable
length and
uniformity.
Finally the officer may have discussion with manager and the
decision have
taken for purchase for high quality & quantity.
Procedure
Godown in-charge is the responsible person for the cotton and
yarn issue. The purchased
cotton stored in godown, which will be separated under the name
of its supplier. The godown in-
charge issues the cotton to the production section.
Out parties account.
Raw materials and stock account.
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LEARNING:
I learned from this department how to purchase the raw materials
from other
countries.
This department takes care of maintaining the raw materials for
its production
process
This department is keen on reducing the maintenance cost of its
inventory. This is
done by maintaining the optimum inventory level.
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PRODUCTION DEPARTMENT
Cotton which is in the form of bale is fed to blow room followed
by various
operation like carding and coming depends on the
requirements.
The Spinning is a technological system in which twist is
inserted to the fibers and
yarn is produced. The spinning process includes many processes
which transform the bales of
raw cotton into a yarn ready for weaving. The term "spinning"
can refer to the whole activity or
just to the final process of making the yarn.
The spinning process is shown in the following diagram.
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PRODUCTION PROCESS
MIXING ROOM:
In spinning mill production the first process is done on the
mixing room. In this
room chemical and water will be spread over the cotton before
entering the machine. In the
mixing room the function of cleaning the cotton and their seeds
and dust is done. 10 to 20
percentage of cotton is cleaned at this department.
Mixing of cotton brought to make a uniform blend in order to
make a uniform
yarn with high quality parameter in order to avoid any shade
problem. For this purpose, the
number of bales is mixed to get uniform results. Raw cotton is
purchased from best Cotton
growing areas of country and also cotton bales are imported from
foreign countries. For stocking
and mixing, sandwich-mixing technique is used.
BLOW ROOM:
At blow room more than 80 percent of dust and seeds are removed.
The cylinder
form of cotton is made i.e. 50 to 60 meters lap. A lap is a
sheet of cotton fleece rolled around an
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iron rod inserted in the lap spindle. When the full lap is
removed from the sketchers, the spindle
is pulled out and the lap remains around the iron rod.
CARDING:
This process is the Heart of the Millwhere converting the
cylinder type cotton
into sliver form is done. The opened fibers are collected by the
doffer comb or the doff roller in
the form of a web. This web is then passed through the trumpet
to give it the shape of a rope and
coiled inside a can by means of a coiler. The rope form of
cotton material is called a sliver.
The card is the most important machine in the yarn manufacturing
process.
It performs second- and final-level cleaning functions in an
overwhelming majority of cotton
textile mills. The card is composed of a system of three
wire-covered cylinders and a series of
flat, wire-covered bars that successively work small clumps and
tufts of fibres into a high degree
of separation or openness, remove a very high percentage of
Trash and other foreign matter,
collect the fibres into a rope-like form called a sliver and
deliver this sliver in a container for
use in the subsequent process.
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COMBING:
Combing is a technique that has been used in the preparation of
textiles for
centuries. Essentially, combing is a process that helps to
smooth and prepare fibers for use
inspinning.Combing also helps to separate short fibers from
longer ones, which also helps to
make the process of spinning much easier. Thecombed cotton will
feel smoother to the touch,
and also produce a garment that will wear longer than a garment
made with uncombed cotton.
A small number of mills produce combed yarn, the cleanest and
most uniform
cotton yarn. Combing provides more extensive cleaning than is
provided by the card. The
purpose of combing is to remove short fibres, neps and trash so
that the resulting sliver is very
clean and lustrous. The comber is a complicated machine composed
of grooved feed rolls and a
cylinder that is partially covered with needles to comb out
short fibers.
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DRAWING:
In order to spin an even and regular yarn the silver should be
uniform and
regular. The fibers should also be made parallel and oriented
along the axis of the silver for
better control of the fibers during drafting in succeeding
process and also for obtaining better
strength of yarn in spinning. The evenness of silver and
parallelization of fibers are achieved at
the draw frame where 6 to 8 or more silvers are blended together
and drafted to get one silver.
The draft will be equal to the no of silvers blended.
Drawing is the first process in yarn manufacturing that employs
roller drafting. In
drawing, practically all draft results from the action of
rollers. Containers of sliver from the
carding process are staked in the creel of the drawing frame.
Drafting occurs when a sliver is fed
into a system of paired rollers moving at different speeds.
Drawing straightens the fibres in the sliver by drafting to make
more of the fibres
parallel to the axis of the sliver. Parallelization is necessary
to obtain the properties desired when
the fibres are subsequently twisted into yarn. Drawing also
produces a sliver that is more uniform
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in weight per unit of length and helps to achieve greater
blending capabilities. The fibres that are
produced by the final drawing process, called finisher drawing,
are nearly straight and parallel to
the axis of the sliver. Weight per unit length of a
finisher-drawing sliver is too high to permit
drafting into yarn on conventional ring-spinning systems.
SIMPLEX:
We have come from blow room to carding to draw frames and now we
enter the
frames department also called as roving department or simplex
department.
Simplex department are used to increase the yarn quality and
strength. The hank
cotton is converted in to bobbin at this department. The bobbins
colors are red, yellow, and ash
color. The hank with bobbin weights is 1kg to 1.5kg each.
SPINNING:
In this spinning department the rover yarn will be more thinned
at this section.
Before the simplex department we called the cotton name as hank,
but at the stage of entering
the hank into the spinning department it is called as yarn. The
spinning department is having
15000 spindles, which helps to making yarn production. The
spinning department converts thebig bobbin hank into small bobbin;
the weight of small bobbin weight to 50 to 55grams only.
The spinning department is converting the 1000 meter hank onto
26000 meter yarn.
Spinning is the single most costly step in converting cotton
fibres to yarn.
Currently, over 85% of the worlds yarn is produced on
ring-spinning frames, which are
designed to draft the roving into the desired yarn size, or
count, and to impart the desired amount
of twist. The amount of twist is proportional to the strength of
the yarn.
The ratio of the length to the length fed can vary on the order
of 10 to 50. Bobbins
of roving are placed onto holders that allow the roving to feed
freely into the drafting roller of
the ring-spinning frame. Following the drafting zone, the yarn
passes through a traveller onto a
spinning bobbin. The spindle holding this bobbin rotates at high
speed, causing the yarn to
balloon as twist is imparted. The lengths of yarn on the bobbins
are too short for use in
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subsequent processes and are doffed into spinning boxes and
delivered to the next process,
which may be spooling or winding.
REELING:
Reeling department helps to create a reeling yarn using for
handloom production.
That is silk sarees, cotton sarees handloom production. It is
the raw material for handloom
products. In this department 12 machines are used for production
purpose.
The following types of reeling are available, they are
a.
Single hank plain reel (SHPR)b. Double hank plain reel
(DHPR)
c. Double hank cross reel (DHCR)
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PACKING:
It is the final process. The finished yarn will be packed neatly
and send to the
customer. The packing is base on the following type
A. Cone yarn weight
o 40 cone = 50kg
o 50 cone = 50kg
B. Reeling yarn weight
o 40 bundle = 200kg (1 = 5 kg)
o
20 bundle = 90kg (1 = 4.5 kg)
LEARNING:
I learned from this department how to twist the different kinds
of yarns.
The production department carries out activities of
spinning.
They have machineries to convert cotton into thread.
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MARKETING DEPARTMENT
Marketing is perhaps the most important activity in a business
because it has
adirect effect on profitabilityandsales. Marketing is basically
your interaction with your
consumer. This interaction with your consumer is done so that
you can get the consumer to
purchase your product or service. Basically that is what
marketing is all about. Marketing should
be done for the right product, in the right place, at the right
time, at the right price.
Distribution area:
Distribution area is all over tamilnadu in polymer industry.
Advertisement:
The advertisement of the company is news paper, business
magazines etc..
Price strategy:
The price has to fix by all person. The product is sold to only
whole seller.
Mode of transport:
The transport of goods is all over tamilnadu. The goods
transport through rail androad ways. The transport of the city is
mini auto and Omni.
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Delivery method:
The delivery of goods is not the free delivery. The amount
charged depends upon
the distance travelled.
Competitors details:
The customers for the products are yarn producer, polymer
industry etc.
LEARNING:
I learned from this department how to do the marketing
activities and also how to
attract and analyze the consumer.
This department has direct contact with all their customers.
The needs of customers are enquired and are satisfied.
Discounts are given to customers in festival season.
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FINANCE DEPARTMENT
Introduction
The accounting department typically handles everything that
keeps the business
running. It depends on the company. For most though, it means
keeping the books. That means
maintaining checking accounts, payroll, tax preparations,
financial statement preparations,
analyzing the companys profitability, meeting with regulators
and auditors, creating budgets,
etc..
Functions of Finance Department
The company maintains a clear and perfect accounting system. The
main activity of
the finance department is working capital management.
Preparation of fund flow statement, cash
flow statement, balance sheet, profit and loss accounts are also
the activities of finance
department. Secretarial work relating to board comes under the
finance department. Most theactivities carried out by the finance
department are preparing to long term and short term
requirement of the operation, closing purchase bill, maintaining
the account contractors,
subcontractors, income tax, deduction, salary discrepancy,
dealing with the financial institutions
with import and exports.
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Accounting system
The financial statements are prepared on historical cost and
convention.
All fixed assets are states at cot adjusted by revaluation in
case of certain land, building,
land and machinery and electrical installation, less accumulated
depreciation.
Long term investments are stated at cost less provision
Values of fixed assets are devalued by technicians
Valuation of investment is done at cost.
Depreciation is done as per the companys act 1956.
Management of Payables and Receivables:
As 90% of the sales are as exports, it takes place with the
support of letter of credit or
bank guarantee. Therefore, management of payables and
receivables has not been a problem for
the company. In this total amount, 50% of the total amount is
written off as bad depts. Likewise
80% of the raw cotton purchased is imported. So L/C is made us
here too. Local purchase is
made by the company for a credit period of 30 to 90 days. The
company claims to have an
efficient management of both payables as well as
receivables.
Investments:
Long term investments are stated at cost less provision, if any,
for other than temporary
diminution in the value of investments.
Inventories:
Inventories are valued at lower of cost or net reliable value.
Cost of Raw Materials is
computed by using Specific identification method and for other
inventories Weighted
Average method. The cost includes costs of purchase, cost of
convention and other costs
incurred in bringing the inventories to their present location
and condition.
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Sales:
Sales are recognized as and when risks and rewards of ownership
are passed on to the
buyer and ultimate realization of price is reasonable certain.
Export sales are inclusive of deemed
exports while local sales are net of sales Tax/ VAT.
Borrowing Cost:
Borrowing Cost attributable to acquisition and construction of
qualifying assets are
capitalized as a part of the cost of such asset up to the date
when such asset is ready for its
intended use. Other borrowing costs are charged to profit and
Loss Account.
LEARNING:
I learned from this department how to allocate the finance to
different
departments and how to maintain the finance records.
The finance department is provided with computers.
Every person is used and entry to the computer.
They maintain separate account for journal, ledger, petty cash,
balance sheet
etc.
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HUMAN RESOURCE DEPARTMENT
Introduction
Personnel Department plays a crucial role in the management of
the company.The department try to create and utilize an able and
motivated workforce to accomplish the
organizational goal, and try to satisfy individual and group
needs by providing adequate and
equitable wages and incentives, employee, benefit and social
security and measures for
challenging work prestige, recognition security, status etc.
The personal department is responsible for recruitment,
selection, placemen
training performance, appraisal, promotion and separation. This
department is headed by DGM
(industrial relations). He is in charge of implementation
systematic recruitment procedures forproviding facility for the
overall development and motivation of all the employees. He is also
in
charge of ensuring safety aspect in the mill and maintaining
cordials industrial relation with the
workers. The categories of workers employees in KUMAR are
permanent and temporary. The
recruitment, employment, leave disciplinary actions, retirement
etc. are done as per the standing
order. This department is also responsible for training,
performance appraisal compensation and
separation.
Functions of personal department
Recruitment and selection
Induction training procedure
Training
Evaluation
Performance appraisal
Wage and salary Administration
Recruitment and selection
Kumar spinning Ltd recruits its manpower resources through
recruitment agencies and
advertisement in leading newspapers. The other sources are form
reference service and relatives
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of employees and from apprentices. Recruitment is done b the
G.M. of personnel and industrial
Relation Department. At Kumar spinning selection is done through
tests and interview.
Induction Training Procedure
Technical and non technical fresh recruits are given general
exposure to the overall
activities of the organization during initial days. There after
they are given in depth training in
assigned areas of work followed by on the job training.
Workmen fresh recruits are given general exposure to the overall
activities of the
organization. They are on the job training under the supervision
of the jobber/ mastery, guided
by supervisors.
Training
Training is given to all workers for developing their skills and
proficiency in work. The
probationary period for also workers and office staff is six
months. A formal induction training
program is provided for fresh recruits as per the program given
in the induction training manual.
Also training is given to each worker when a new machine is
installed respective to their
department.
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Evaluation
On completion of training an evaluation regarding effectiveness
of training received is
sought from the department concerned.
Wage and Salary Administration
KUMAR follows time rate wage system. For this purpose the
attendance records are
maintained strictly also there is card punching system for
recording entry and exit of the
employees and workers. The remuneration for the work of service
rented by the employees is
paid in the form of salaries, wages or fringe benefit. Wages
include both monetary benefits and
non monetary benefits. There is no PF and ESI for over time and
holiday work.
Employee welfare schemes
The company provides all the statutory welfare measure as per
the factorys act 1948.
There are general measures and the company also administers
activities that come under non-
statutory items.
Employee credit society
Kumar spinning employees credit society advanced loans to the
employees ranging fromRs. 2000/- to 25000/- for various purposes on
a reduced rate of interest. They also run recurring
deposit schemes for the employees.
Holidays
Each employee can avail 13 paid holidays in a calculating year.
List of holidays will be
notified each year.
Canteen
A subsidized canteen managed by the employee representatives is
taken care of catering
needs of the employees. Meals, snacks, coffee/ tea are available
in the canteen during the
prescribed timings.
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Safety
Safety, housekeeping activities are arrived out on a continuous
basis. A part from the
statutory compliance; a safety committee is effectively
working.
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Employee welfare fund
There is fund constituted for the welfare of the employees.
There are different benefits
like death benefit, retirement benefit, disablement benefit,
loans assistance, etc.
Assistance for the handicapped children
There is a scheme to assist the handicapped children of
employees; this includes supply
of artificial limbs, aids or any other assistance to such
cases.
Blood Donor Group
Blood Group of almost all employees has been ascertained. In
case of emergency,
employees will come forward to donate blood.
Suggestion scheme
The company conducts suggestion scheme in the areas of
productivity, housekeeping,
quality, safety, etc. employees who submit suggestions are being
properly rewarded
Attendance award
To recognize the employees to attend word regularly special
prices given every year.
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Subscription to News Paper and Journals
Various News papers and journals are being subscribed for the
benefit of employees
Standing orders
There is an approved standing order, which regulates the
conditions of employment
Excursion tours
Excursion tours are arranged regularly for the staff member and
for the participation the
workers education classes
Health and safety
There is a safety committee for looking after the safety of the
workers drinking water
facilities are priced different spots inside the company.
Employee state insurance scheme
ESI scheme is unique multidimensional self financing social
security scheme in which
every contributor is a benefactor and beneficiary. This
integrated scheme of health insurance
prides comprehensive medical cover and cash benefit in
contingencies of sickness, maternity,disablement and health.
LEARNING:
I learned from this department how to recruit the employee and
how to evaluate
the performance of the employee.
Most of the people working here are aged more than 40 years.
Only people operating a computer system are young employees.
Employees here have enough experience.
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QUALITY ASSURANCE DEPARTMENT
Introduction
Quality control is a process by which entities review the
quality of all factorsinvolved in production. This department
should be in every firm for preventing errors before the
product reaches the hands of the customer.
Functions:
This help to check the quality of each product.
It is also helps to find damaged product before delivering the
product.
Every employee is expected to take responsibility for managing
quality issues
in order to make sure that waste is minimized and quality
maximized.
Quality Policy
Kumar spinnings would ensure manufacturing and marketing of
cotton yarn by
complying with:
Kumar spinnings ltd. would achieve the highest level of customer
satisfaction by meeting
their stated and perceived requirements manufacturing
consistency and timely delivery.
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Kumar endeavors continual up gradation of product quality and
technology supported by
R &D efforts in a cost effective manner.
Kumar would inculcate a sense of quality awareness at all levels
by using appropriate
training and motivation techniques.
Kumar would aim at preserving the environmental conditions y
adopting eco- friendly
measures in its manufacturing and other activities.
The man activities of QADare:
Raw material selection and stock
Bale management
Online process monitoring of production and quality.
100% zero/ quantum clearer
UV lamp testing
AWARDS OF THE COMPANY
Best implementation award in 5s technique.
ISO 9001:2000 certified award in the year 1990.
Quality implementing has started in the year 1994.
TPM is implemented in the company.
LEARNING:
I learned from this department how to produce the finished goods
based on
customer spefications.
How to increase the good quality maintain the department.
How to improve the quality and maintain the quality of
goods.
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ENGINEERING DEPARTMENT:
Engineering Department is engaged in the following maintenance
work.
Machine maintenance:
Machinery repairs & break down
Utilities maintenance:
Generator, boiler, chilling, plant & pumps mould machine,
Mixture Machine
Drop door & Two Roots etc.,
Civil maintenance:
Civil maintenance means there proper furniture should be
provided for the office. There
may be many breakage in the furniture new furniture should be
replaced for that one. A garden
should be properly maintenance.
A factory should be clean from the dust and fumes. The window
and wall should paint
once in a year. Where the working climate is very hot so air
conditions, air coolers, fan should
be provided.
Environment maintenance:
The Environment maintenance means an chemical and water can be
properly treating.
Dye water should be kept as clean once in a week. Reduce
recycle, reuse and properly dispose
all the wastages.
LEARNING:
I learned from this department how to maintain the machine and
power equipments.
How to maintain the machinery in production area.
How many times to service the machinery in the year.
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OFFICE MANAGEMENT:
Office is a administrative centre for a business. The main
purpose of office is to
provide the service of communication and record keeping.
The factory maintains & office stationary is pen, pencil,
carbon, stamp pad, paperweight, written pad etc.
The office equipment is used to the computer, printer,
telephone, calculator,
daybook to be maintaining the office.
OFFICE EQUIPMENT:
Computer:
A computer is used to the entire department is an important in
company. The record
and day-to-day transaction and other details of the factory are
computerized.
Printer:
An ink-jet printer is used in the factory to take important copy
of records and bill
vouchers.
Telephone:
An intercom is provided to the department to have a
communication with all thepersons.
Calculator:
The factory provides calculator to the finance, production and
purchase department.
Day book:
a day book is maintained regularly to record all the petty
expenses and daily report.
Filing:
Various files are maintained in the a-z method. The files were
checked and verified once in
a week.
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CASE STUDY
Problems observed in spinning industries:
Power system apparatus over heating:
It is normally observed that transformer gets overheating extra
fans near transformer and
at places water sprinkler are installed to cool the transformer.
Long term distribution panel doors
are kept open and cooling fans and even air conditioning of
panel room is carried out to cool the
switch gears, bus born in the room. Bursting of provident fund
capacitors due to excessive
harmonics was reported. Over correction of provident fund
leading to increase of long term
voltage has damaged the sensitive components of VFD used in
machineries.
Detailed harmonic measurement study on presence of harmonics and
their effects onmore than 20 textile industries have been carried
out. Following table shows the percentage. The
content present at the PCC of various machineries. The heating
of power transformer in the
presence of harmonics analyzed. The theoretical calculations of
heat loss along with the
measurement were carried out. Fifteenth National Power System
Conference (NPSC), current for
spinning mill machineries.
Conclusion:
The maximum savings due to cancellation on of harmonics from the
power transformer
comes from the eddy current loss component of the total load
loss of the transformer. This eddy
current loss increases with the increases in current THD came
down to 15% at the secondary of
the transformer due to other feeders supporting linear loads
powered by the same transformer.
The saving in energy can be up to1% of the rated load capacity
in spinning mills where variable
frequency drive with 6- pulse rectifiers are used. The savings
may further come down with the
advent of new technology for improving the eddy current losses
for the transformer.
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SWOT ANALYSIS
The SWOT analysis is an extremely useful tool for understanding
and decision-making for
all sorts of situations in business and organizations. Itis
astrategic planning method used to
evaluate the Strengths, Weaknesses, Opportunities, and Threats
involved in aproject or in
abusiness venture.
STRENGTH:
1. Effective management.
2. Quality of production.
3. Products are well accepted in the market.
4.
Satisfactory organizational set-up with experienced and
well-qualified employees.
5. Experienced promoters in the industry
WEEKNESS:
1. Lack of transportation.
2.
Lack of infrastructure.
OPPORTUNITY:
1. Increasing demand of yarn for local oriented production.
2. New customers.
THREATS:
1. Competition in domestic market
2. Changes in Government policy regarding taxation and related
matter.
3. No government support for textile industry.
http://en.wikipedia.org/wiki/Strategic_planninghttp://en.wikipedia.org/wiki/Projecthttp://en.wikipedia.org/wiki/Businesshttp://en.wikipedia.org/wiki/Businesshttp://en.wikipedia.org/wiki/Projecthttp://en.wikipedia.org/wiki/Strategic_planning
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FINDINGS
There is poor communication between employees and
management.
There are no new machines in the company; this company is not
able to purchase new
machines due to finance problems.
Frequent power cut affects the production.
The fire accident safety measures are not provided
SUGGESTIONS
To improve the good communication between employees and
management.
To apply loan for financial institution to purchase new
machinery and produce good
quality of product.
Regular supply of electric power should be made available
without any fluctuation. So as to
facilitate the continuous flow of production in the factory.
The fire accident safety measure has to be provided in the
factory in dangerous area and also to
provide emergency exit.
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CONCLUSION
The trainee came to know about the several concepts of business
administration,
functions of a manager in various situations and relationship
between the employer and
employees. The training period was very useful and beneficial to
the trainee. The trainee has got
great experience and acquired knowledge in this inplant
training. During the training period,
Accounts Department helped the trainee to gain more
knowledge.
The training is a good opportunity for the trainee to gain
practical work knowledge. The
unit maintains good co-ordination with various departments such
as Purchase, Sales, Finance,
HR and Production. It is helpful in future to work in any
organization and understand the
activities of department.
The proper training provided the trainee creates sense of
confidence and coordination.
