23720824 total quality managment

8/8/2019 23720824 Total Quality Managment

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TOTAL QUALITY MANAGMENT SUPERIOR

DEDICATION

We are dedicating our work to our parents andrespected teacher Prof. Bilal Rauf, who have played a

vital role in our studies and have guided us at every

step with their precious ideas. No doubt this

dedication is insufficient and we can never repay for

the role they have played in our studies but we aresure that their work will prove itself an asset in our

life


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ACKNOWLEDEGMENT

We are very thankful to MASTER GROUP OF

INDUSTRIES which gave us valuable information. We

pay gratitude to staff giving valuable information.

We are also very thankful to Mr. Imran Khan who

helped a lot us by giving up to date information.

We are very proud of our teacher Prof. Bilal Rauf

whose help and instructions enable us to bind papers

into project manner. We are very thankful to him.


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PR EFACE

The most beautiful things we can experience are the

mysterious .It is source of all true art and science (Albert Einstein, 1930)

This project is based on the topic which is assigned

to us by our respected teacher Prof. Amjad, the

organization which we took for research is:


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FINAL PR OJECT FO R TQM

We have selected Master Group of Industries for TQM Project.

Company Introduction:

Master Textile is one of the foremost and leading textile

manufacturers, based at Lahore, Pakistan. Engaged in the export of

quality products like: Yarns, Fabrics, Garments and Home Textile. We

have established a name of credentials owing to the project

commitments, working speed, quality practices and the overall

approach of the company. Our Operating philosophy is to provide

buyers with product that meets their specification, reliably delivered at

a reasonable price in Domestic and International Markets. We offer our

customers a global network of opportunities and the best deal

possible.

Company History

Master Group of Industries was established in 1963 as a joint venture

with Bayer A.G. of Germany to manufacture foam mattresses. Today,

the Group is one of Pakistan's most dynamic Industrial concerns

commanding well over 50% of the domestic foam market. Even

though the Group's mainstay is foam products, it as rapidly diversified

into other areas such as Textiles, Auto-motive parts, spring mattress

production and General Trading. The group has a fixed asset base of

USD 20.00 million, annual turnover of USD 60.00 million and 2500


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employees. The Master Group enjoys impeccable integrity both in the

international and domestic markets.

MissionOur goal is to strengthen the exports from Pakistan. With this comes

the challenge of achieving international quality standards for both

weaving and dyeing/finishing. Master textile was not only able to

achieve these standards, but in fact raised the benchmark for both

quality and reliability from Pakistan. The first of its kind state-of-art

composite unit in Pakistan was testament to the commitment of the

groups 30 year old motto of quality and reliability. The company isstriving to have socially accountable and environment friendly

operations and practices.

Vision StatementThe groups vision program includes expansion of the weaving, Dye

house and garment facilities. We see the broader challenge and

opportunity to increase our share of international business as the

world moves toward globalization. We are developing poly mattresses,

cushions, quilts, bed sheets, bed spread, napkins, wadding, and non-

woven fabric facilities. We aim to invest in future focusing on the

customers needs and intense competition in the international markets.


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CASE STUDY

CE R TIFICATION

The master textile has successfully implemented Total quality

management and has rewarded with following certificates.

SA-8000

ISO-9001


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ISO-14001

OEKO-TEX


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Environmental P olicy

y Prevention of pollution.y C omplying with suitable applicable environmental regulations.

y Setting environmental objectives and management programs.

y In-house and public awareness.

Quality P roducts are our responsibilities and right of customer.

y Aiming at the highest level of performance by adoption of

modern resources.

y Train staff and workers for achievement of Excellence in Quality

Assurance.

y Welfare of workers and making valuable contributions to the

economy.

y Support and improve good working practices.

Social P olicy

Master Textile Management is committed to provide and continuously

improve socially and legally accountable practices under SA-8000.


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B usiness Operations

Yarn

Greige Fabrics

Based on Air Jet technology our weaving facility has a production of

50,000 meters per day. We are capable of producing fabrics both in

narrow widths for Apparel and wider widths for Home Textiles. Weregularly manufacture Twill, Drill, Poplin, Satin, Rip-stop and Dobby

design fabrics. Yarn counts range from 6/s to 45/s in both cotton and

various polyester cotton blends. We also manufacture fabrics using

two ply yarns. To ensure that the fabrics are of the highest standards

our in-house laboratory regularly test yarns for count variation,

imperfections and tensile strength.

Only after a satisfactory result is the yarn issued for consumption.After production, we are also equipped to check the fabric's weight,

construction and tensile strength. The fabric inspection and grading is

checked on the Barco computer system. In addition to this our

customers have a choice of different inspection standards like the


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Japanese 10 point system, European 4 point system and American

AT CC 10 point system. The inspectors are also trained to maintain

high customer and textile industry standards. We endeavor to provide

our customers with long fabric lengths of up to 800 meters on rolls.

Dyed Fabrics

Master Textile has been supplying Dyed fabrics for the last three years

to various quality conscious companies worldwide. We are capable of

supplying fabrics with specialized finishes such as Sanforizing,

Emerizing, Mircro Sanding, Resin, Air Permeability, Wrinkle free and

Scotchgard. Our fabrics adhere to all internationally acceptedstandards. We regularly provide our customers with fabrics achieving

light fastness of 4-5, color fastness, rubbing fastness and dry cleaning

fastness of 4-5. in order to meet the customer's individual quality

standards and finishing specifications, only imported European

Dyestuffs from companies like Dystar, C iba and C lariant are used.

The fabric is inspected by our quality controllers at every stage

of finishing. We use reactive, Vat, Sulpher and pigment dyes for 100%cotton fabrics. Polyeseter blended fabrics are dyed using disperse with

reactive or pigment dyes. Special care is taken during packing to

ensure that piece lengths meet or exceed customer requirements.

Products made from our dyed fabrics can be found globally in chain

stores such as Marks & Spencers, Steffanels, C &A, BHS, etc.


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P rocessing DivisionMaster Textile has been supplying Dyed fabrics for the last five

years to various quality conscious companies worldwide. We are also

supplying printed fabrics for upholstery and apparel use. To satisfy our

customers requirements, we have set-up our own Dyeing and

Finishing Plant. We are capable of supplying fabrics with specialized

finishes such as Resin, Air Permeability, Wrinkle free, Teflon, high

visibility and flame retardant. Our fabrics adhere to all internationally

accepted standards. We regularly provide our customers with fabrics

achieving light fastness of 5-6, color fastness, rubbing fastness and

dry cleaning fastness of 4-5. In order to meet the customers

individual quality standards and finishing specifications, only imported

European Dyestuffs are used. We use sulpher, reactive and vat dyes

for 100% cotton, disperse with reactive or VAT dyes for Polly-cotton

fabrics. We have installed following machinery with workable width of

72 in the finishing mills:


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Apparel divisionThe garment facility is equipped with 200 stitching machines, and is

located in Karachi; with all necessary facilities to produce casual

sportswear and industrial work wear garments. This stitching unit is

set up on the chain method of production and is capable of producing

2000 garments a day. At the heart of the unit is the Switch Track

Overhead Hanging System to manufacture garments in an efficient

and clean manner. We offer various types on garment finishes such as

Stone, Enzyme, Bleach, Sand, Sandblasted, Silicon, etc.

State-of-art computerized, pattern making and grading machines, as

well as computerized stitching machines are installed to produce high

quality garments. The garments produces includes trousers, shorts,

jackets, blouses, dresses and work wear articles such as Overalls,

C overalls, Bib-Brace, Trousers, Doctor C oats, Blouses etc..

C urrently, we are shipping casual garments to companies like C &A,

Kaufhof, C arrefoure, Taco, Primark and Newlook. Work wear garments

are being supplied to leading European companies. During the process

of stitching we have in-line inspection and final inspection process both


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of which conform to the AQL 2.5 system. Master Textile Mills Ltd is

your one-stop Partner for all your garments requirements.

CAD/CAMSome C AD/ C AM text GOES here ...

Cutting C utting units working under the

supervision of skilled unit managers, these cutting units are well

equipped with latest machinery including Bullmer Plotter, Spreader and

C utter etc.

Sewing

With over 750 stitching machines, manned with the most skilled and

expert operators, Master is capable of producing about 120,000

dozens per month versatile garments ranging from basic to high

fashion, mens, womens and kids with maximum flexibility in size and

color assortments. The Quality control and Quality Assurance

departments are in place to make sure the companys objective of zero

defect. C omputerized Bar coding and Back Track systems provide

Master 100% predictability and tracking performance.


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5 S in B low R oom:

SEI R E In the blow room cotton is feed. After feed the unwanted

items likes trash particular are collected and disposed.

The trash particular includes puppy trash, seeds, husk, jute, and poly particular.

SEITON In blow room there are difference kind of cotton is

placed at there specified areas it is necessary to avoid

the mixing of different kind of cotton because it result in

the variation of varn. The flour is also painted to specify

the area boundaries for each cotton walls.

SEISO The blow room is kept neat and clean so that the dustand other contamination is might not mix with cotton.

The blow room is also provided with suction fans which

removes light particles from cotton and environment. In

Master Textile there is also a dedusting machine is

incorporated and perform same function.

SUIKETSU The supervisors and assistant spinning managers are

provided with checklist to coordinate it with non-

managerial staff. The checklist includes the routine

activities that the shift In charge has to perform before

starting the shift. In blow room the checklist includes,

following

1- Machines physical checking.

2- Oiling and greasing of major components.

3- To check the program feeded in the machine andcompare it with the planed program.

4- To neat and clean the main components of the

machine.


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5- To set and arrange the equipments required to runthe machine.

SHETSUKE In Master Textile on job training is carried out by

training instructors. On each level training is carried out.The managers are trained to coordinate work with the

employees similarly the non-managerial staff is trained

to operate machines and other processing activities.

Card:

It consists of Rieter[Swiss] card machines c-51 hi-per & Trutzscheller

Dk 803. It opens the cotton and removes the dirt, dust, and foreign

matter and produces silver in cans for feeding to draw frames. These

cards are with chute feed system and auto leveling to produce high

quality of yarn.


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5 S in Carding:

SEI R E The cotton laps are feeded to carding section. The

defected cotton laps are removed.

SEITON In Master Textile there are 2 Blow room lines so the

material obtained from these 2 lines are kept apart from

each other. The flour is also painted and the lap of the

particular cotton is also specifically placed.

SEISO The carding machine is kept neat and clean from inside

and outside. The sliver drums are also kept neat and

clean so that the trash might not be mixed with sliver.





starting the shift. In blow room the checklist includes,

following

1- The sliver cans should be neat and clean.

2- The Oil and grease should not be in contact withsliver.

3- Do not touch sliver and press sliver with hands. 4- To neat and clean the main components of the

machine.


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5- To keep the sliver of particular cotton at theirspecific place.

SHETSUKE In carding there are different notice boards to aware the

non-managerial staff. The precautions are there tohandle the material and machinery. The general

supervision is also carried out at regular interval of time.

Draw Frames:

It consists of Rieter[Swiss] machines SBD-10, RSBD-30, SB-2. These

machines parallelizes the fibers and improves uniformity of produce

even yarn on ring. These drawings are with auto levelling system.

5 S in Draw Frame:

SEI R E The drums of different cottons can be identified by their

specific color. Mostly blue and red cans are used. The

defective cans are removed with regular intervals of

time so that the quality of sliver is not disturbed.

SEITON In Draw frame the sliver cans are feeded to Drawing

machine. They are arranged in a specified area which is

marked by paint. The drums are arranged in line.

SEISO The Draw frame is also kept neat and clean. The oil and

grease is also avoided with the material.

SUIKETSU The sliver from drum should not be interrupt with each


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other. It should not be treated harshly. The empty

drums are removed and send to carding department for

coiling.

SHETSUKE The quality of sliver is checked after regular interval of time. The samples are taken to laboratory.

Simplex:

Toyota FL-100 type machines are currently in operation in Simplex

sector. Special type of Flyer on machines is installed to get even

quality roving.


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5 S in Simplex:

SEI R E 40-60 cans are feeded in the simplex machine. It has

120 spindles having roving over it. The cans re arranged

in a sequence. The old and defective cans are tagged.SEITON The draw frame sliver cans are feeded to roving

machine. It is necessary to keep them in a particular

order and their mentioned place because the crossing of

sliver cans of different cotton creates the variation in the

final count of yarn.

SEISO The simplex is also kept neat and clean. The oil and

grease is also avoided with the material.

SUIKETSU The simplex roving is obtained from simplex machine is

hanged over a creeling stand and transfer to ring

department.

SHETSUKE The quality of sliver is checked after regular interval of

time. The samples are taken to laboratory.

R ing:

TOYOTA Ring Frames work round the clock at ring section. SKF PK-225

drafting system is attached on these Ring frames. LUWA Air

conditioning systems in Ring department maintain the required R.H

and temperature in the whole ring department to maintain low

hairiness in yarn. C ots, Apron and Steel rings of machinery is changed

at proper time.


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5 S in R ing:

SEI R E The roving is feeded to ring frame. The defective

parts and roving is removed

SEITON The roving is placed over their specific creeling

position. There are 1024 spindle over a ring

frame. The Bobbins are fitted over spindle.SEISO The ring frames are also kept extra ordinary neat and

clean. The machine is provided with suction ducts to

remove fluff.



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starting the shift. In blow room the checklist includes,following

1- The ring frame should be neat and clean.

2- The Oil and grease should not be in contact withsliver.

3- Do not touch roving and press sliver with hands. 4- To neat and clean the main components of the

machine.To keep the sliver of particular cotton at their

specific place.

SHETSUKE In Master Textile on job training is carried out by

training instructors. On each level training is carried out.

The managers are trained to coordinate work with the

employees similarly the non-managerial staff is trained

to operate machines and other processing activities.

Auto Cone:

We installed new 21 C Process C oner. We are producing yarn having

low level of contamination. It is a fully computerized system and helps

to determine departmental efficiency round the clock. Yarn hairiness is

controlled on 21 C Process C oner by its special balloon system.


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5 S in Auto Cone:

SEI R E The defective bobbins are removed from ring

frame. For each count the bobbin is given a

special number. The bobbins of different color

should not mix with each other. The defective

bobbins are disposed.

SEITON In auto cone machine the bobbins of same color are

creeled. The machine is also marked for specific count of

yarn.SEISO The auto cone machine and yarn cone are kept neat and

clean. The waste obtained from each department is

removed

SUIKETSU The standards for each process are mentioned.


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Suggestion & recommendation

The most of employers have not better idea of TQM in master Textile. They need training.

The non-managerial staff doesnt know that they are applying 5Stechnique in their working area. They need to aware relate their work with 5s technique.

All information boards should also be mentioned toimplementation of 5S technique.

The managerial staff has to exchange true ideas of 5s withworkers, So that they can perform well.

The first line managers need to motivate so that they cancoordinate better with non-managerial staff.

New employers trained about their jobs with little knowledgeabout TQM. The up coming employers should also be completelytrained about 5S implementation.

The notice board need up gradation, they should be up-to-date.

Specially formatting of these checklist boards should be user friendly.

The most of supervisor are not highly educated, when we talk about TQM and 5S with them, they were disabling to explain it.So we think that their training is also required.

23720824 total quality managment

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