project repot - rivaa exports
TRANSCRIPT
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Contents
Objective: ................................ ................................ ................................ ............................. 3Introduction: ................................ ................................ ................................ ......................... 3Analysis Of Plant Location Considering Various Factors ................................ ...................... 5Utilities Of Production And Their Availability: ................................ ................................ ..... 6Organization Structure Of Production Department ................................ ................................ 8How Production PlanIs Prepared From Sales Plan................................ ................................ 9How Production PlanIs Converted In Material Requirement Plan And UltimatelyIn PurchasePlan: ................................ ................................ ................................ ................................ ..... 9Material Receipt Procedure: ................................ ................................ ................................ 11MaterialIssue Procedure: ................................ ................................ ................................ .... 12Purchase Procedure: ................................ ................................ ................................ ............ 12Inventory Control System: ................................ ................................ ................................ .. 13Different Records Kept In Store: ................................ ................................ ......................... 15Types And Classes Of Material-Handling Equipments: ................................ ....................... 16Classification OfInventories According To Abc Analysis And Ved Analysis: .................... 18Maintenance Planning System: ................................ ................................ ........................... 20Records Related To Production Operations At Different Machines: ................................ .... 21Production Process................................ ................................ ................................ .............. 24List Of Plant & Machineries: ................................ ................................ .............................. 33
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Objective:
To observe and understand the production process ofa dyeingand printing mill.
Introduction:
Rivaa Exports Ltd. isalimited company incorporated in the year 2001. The company isset
up with the main object of manufacturing, processingand marketing of dyed, printed andembroidered fabrics. RIVAA is one of the renowned names in textiles, which has domestic
and overseas market clientele. Inshort span the companygot the status of Governmentrecognized STAR EXPORT HOUSE. The company markets its product under the brand
name Rivaaand got registered with Registrar of Trade Mark, Government ofIndia underclass 24 and 25.
The Registered office of the Company isat Rivaa House, Udhna Darwaja, Ring Road, Surat,
Gujarat,India. Facilities for Embroideryare at Survey No. 4& 8, Village Sonari,
Sachin, Surat, Gujarat and at Plot No.A-5/1, HojiwalaIndustrial Estate, Sachin PalsanaRoad,Vanz, Surat, Gujarat. Dyeingand Printing division isat Plot No. 803/1, GIDC, Sachin.
Rivaa Exports is equipped with world class technologiesand modern manufacturingmachineries to provide best quality products to our esteemed clients.
The company has been founded by the visionary entrepreneur Shri. Harish Virmani. He is
one of the renowned personalities in the textile businesssince 25 years. He hasstarted hisbusiness carrier inyear 1984-85, his innate ability to foresee the future, closelyanalyzingand
understanding the nuances of day to day operations, quickand rapid implementation, helped
him to build a company with strong foundationsand corporate ethos.
The Directors possess high business caliber, talent, intelligence and high businessacumen
along with rich and vast practical experience. Enriched and well-established reputation of thepromoter withinand outside the country has enabled the company to achieve the desired
results.
The Management of the company is well experienced in the textile industryand is quality
conscious. To lookafter the entire operations, the company has built technically qualified and
experienced team ofassociates. The management rests in the capable hands ofan expert
team,grounded in the realities of the business. With decades of experience, theyare highly
knowledgeable about each and everyaspect of fabric, dyeing, printingand embroideries.
The Company is into manufacturingand exporting of Textile Fabrics especially value addedladies dress materialsand Sarees.. The company has fully computerized Embroidery unit
comprising of Swiss Made Schifily Embroidery Machines, Chinese/Japanees made Multihead, Laser Cut, Cording, Tapping Embroidery machines. The company hasIn-house
Research & Development Department for developingnew designsand patternsand toimprove the quality of the products, to innovate and to touch new paradigms of designsand
concepts.
The company has its presence in PAN India, USA, Canada, U.K., Middle East, Malaysia,
Singapore,Indonesia South Africa, etc. Some of our precious Local buyersare SDM Fabrics
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Pvt. Ltd (TACFAB), Chabra Trading Company Ltd. (CTC)Delhi, Nalli Silk Stores, ShriKrishna Collection, Pothys, The Chennai Silk- Chennai, Sarthas- Trichi, Neerus-
Hyderabad.
The entire organization of the company thrives hard asa team to achieve new goalsand to
meet the challenges of the future by continues improvement and implementation ofnew
methods under the able leadership of Managing Director Shri. Harish Virmani
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Analysis OfPlant Location Considering Various Factors
Forany production unit location of plant also play important role in profitability,so location
should be co operating with various factors. As each coin has two sides there are both
positive and negative points of plant location but positive point is on heavierside. Theyareexplained below inshort.
POSITIVE FACTORS:
y The location of unit is in the outskirts of Surat city which 100% suits the governmentnorm. According to government rule production unit should be away from the
residentialarea.
y Being in the outskirtslocation isnot much far from the main textile market where allthe customers exist.
y Also the entire suppliers production unit of colours, chemicalsand othersare in thesurroundingarea only.
y Labour are easilyavailable here because majority of la bour class workers dwells innearbyareas only.
y At thislocation the company isnot required to install the waste water treatment plant,which isa very major concern fora textile mill in terms of cost and its management.
Because in Sachin a common waste treatment plant is installed by the government
which isnot present in otherlocations of the city.
NEGATIVE FACTORS:
y Mainnegative point here is the availability of water. Here boring water is too hard tobe used for dyeing purpose. So companies here use watersupplied by Sachin GIDC
which increase anominal cost to overall cost. Boring water can be used but onlyafter
some treatment. The totalaverage required quantity per day is 10-11 lakh liters. Many
a times this requirement isnot met due irregularsupply of water from the GIDC. So
to cover the gap water tankers from private suppliers are ordered which further
increases the cost.
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y Other problem is staggering problem. There is a power cut here every week onSaturday. So company has to eitherstop production orgenerate power by their own.
Utilities OfProduction And Their Availability:
Power Generation
The company has connected a power load of 650 KVA with GEB which shows maximum
limit of utilization. The company hasalso installed two D.G. set each of 200KVA, 600 KVA
respectively,so as to ensure continuity of production during power failures. The company
also has one steam turbine attached with boiler which generates 300 KVA of power. Daily
average usage of electricity isaround 9000 to 9500 units per dayand the average monthly
power bill comes to around 12-13 lakh per .
Steam Generation
Boiler is used to generate steam. Boiler issaid as the heart of the dyeingand printing unit and
steam as running blood. Almost on each machine except stentersteam is used ina dyeingand
printing firm. The boiler used here isnamed as F.B.C coal fired combine bio drum HP boiler.
Its capacity is 5 TPH (Ton per Hour). Water used here should be as hot as 80 degree
centigrade.
Raw Material
The ma jor raw materials required are colours and chemicals such as polyester threads,
sodium chloride,sodaash,naviline,solventsacidic acid, blue coat, cotton citric acid, caustic
soda, dispensingagent,levelingagent, etc.
These are manufactured by manysmallscale unitsand a few big industrial houseslocated at
surat and surrounding towns which are manufacturing these colours and chemicals. All the
essential raw materialsare available inadequate quantity, in Surat and Atul. Those units that
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are located outside are having their stores at Surat. Majority of the colour chemicals is
supplied bya companynamed Colourtex, which isa market leader in this industry.
Coal & Gas
Imported Coal is main fuel, which the company already has sufficient connection with the
localsupplier of the same. The daily consumption of coal is 12 to 14 tonapproximately. Gas
is supplied by Gujarat Gas Company for immediate firing purpose in the boiler. Gas
consumed is 4000 cubic/meter.
Transportation
The company hasalready bought for itself two big tempos. The private tempos really help the
company forsmooth flow ofgoods to its customer, without any disturbances (e.g. strike).
Water
The water is been made available to the unit by Sachin GIDC. Total consumption of water is
8 lakh liters per day for dyeingand around 3 lakh liters for printing purpose.
Manual Labour
Forsufficient and successful operation of the project, the units propose to employsufficient
staff for working on two shifts. There are around 800 people working in the company.
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Organization Structure OfProduction Department
OTHERS TECHNICIANS
ENGINEERS MAINTANANCE
DYEING
MASTER
PRINTING
MASTER
ASSISTANT
MASTER
DYEING
INCHARGE
SUPERVISOR
LABOUR
CONTRACTOR
WORKERS
ASSISTANT
MASTER
PRINT
INCH-
ARGE
SUPER-
VISOR
LABOUR
CONTRA
CTOR
WORKERS
PROG
RAM
MERS
PRODUCTION
DESIGNERS
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How Production Plan Is Prepared From Sales Plan
Production Plan isa very important factor related with productionactivity. The process of
preparing production plan from sales plan in dyeing industry is knownas programming.
The customer first ofallgivesgrey cloth in the mill but doesnot give order for designsand
colour combinationat the same time. But then, production manager i.e. master doesnot wait
for his order. He starts the dyeing process which is obvious procedure which isnot dependent
on designs or colour. After this process is completed the grey cloth isnow said as bleached
fabric. This bleached fabric isnow kept in the white department till the designsare finalized.
When customer finalizes the design,and thenstarts the printing process on first come first
serve basis. Some times on demand of regular customers, priority for early production is
given. Production plan is of course planned considering factorslike process time, due date
and available time.
How Production Plan Is Converted In Material Requirement Plan And
Ultimately In Purchase Plan:
Material requirement planning is generally a program which shows the quantity of raw
material that is required for the fulfillment ofa particular order. It satisfies the requirement of
production department ofaccuratelyallocating the raw materials to a particular order.
Once production plan is prepared, production is to be stated but for that raw materials are
required. So now the furtherstep is to calculate the requirement of inputs without which the
production cannot begin.
Whenever the orders are received from customer they are jotted down in the form of an
accurate production plan and sent to the concerned supervisor. The production manager,
machine supervisorand the store manager work in coordination and lookout for the inputs
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required for productionand also analyses the production plan to find out the capacity of the
machine.
They calculate the material requirement by considering the quantity required for one unit of
output and then device the requirement for entire output. The current stock level, pending
purchase order of raw material isalso administered.
Thus the planners first collect all orders, analyze them & finally give the material
requirement quantity. This material requirement is sent to purchase manager through a
purchase indent. He then verifies the order with the store and then places the orders.
Example
BILL OF MATERIAL:
STEP 1: End product
Saree 1 unit
STEP 2: Requirements to make end products
Usable Gray 1meter
Dyeing process
Printing process
STEP 3: Requirements for drumming of gray
Caustic 7 grams
Soda Asn 1 gram
Hydro .375 gram
Stain Remover .25 gram
SWL .15 gram
STEP 4: Requirements for dyeing
Colors (Vary)
Chemicals 0.15 gram
DFT .2 gram
STEP 5: Requirements for printing
Color 687.5 gram
Chemicals 687.5 gram
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Gum 41.25 gram
Water 875.00 gram
Material Receipt Procedure:
Whenever the material is received from the suppliers the security checks the invoice (challan)
& records it in the inward register.
This is then notified to the concerned store manager who verifies the quantity of materialreceived & records it in his inward book.
The informationlike the name of item & its rate quantity is recorded in the stock register.
People from the quality control department check the quality of the received materials
through the various methodslike laboratory testing.
If the quality isacceptable the challan & billsare sent to the purchase department to continue
with the further process of materials.
Rivaa Expots doesnot purchase the grey cloth. The customerssend their owngrey cloth to
them. When the grey cloth is received in the company premises the quantity is counted.
Then the material is marked customer wise, giving the date of receipt, customers name,
givinglot no., etc with the marker. Same information is then recorded in the material inward
register.
The grey cloth is thensent to the grey cloth store. The company canstoreabout 15 to 20 lac
meter ofgrey cloth in theirstores.
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Material Issue Procedure:
Material issued from the factory isgenerally the finished fabrics orany equipment going out
for repairing. In fabric case the security man daily counts the finished rolls while it isloaded
in the tempo and makes the report regarding this. Also person from excise count the rollsand
prepare the different report. When these reports are prepared they are shown to senior
managerand when theygive greensignal then only fabricsare send out of the gate. Ifany
material is to be sent outside for repairing first it is confirmed by the security with the
concerned engineerand further he notes it in his report book which finally is dispatched to
the manager.
Material issue procedure isassimple as the receipt whenany material is issued from the store
by the store keeper for production use it is issued on the basis of the requirement of the
material signed by the supervisor. On issuing the entry of outward is made in the book
against which the quantity, quality,name of the machine on which it isgoing to be used is
mentioned. Assimilar to receipt procedure, even the issue of the material is mentioned on
computersystem.
Purchase Procedure:
The time, quantity, buyer and other factor plays important role in efficient purchase
procedure. If everything goes right it helps a lot to firm to increase its profitability. The
purchase procedure is explained inshort below.
As we have studied the head of colourstore and maintenance store preparesstock register by
them. Theyare the best person who knows regarding the available stock of particular material
and its daily usage. They better know when to re order particular material. They weekly or
sometime daily prepare a report regardingshortage of materials. Theyalso checkany pending
order is made forsuch product ornot and present the report before the general manager.
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If the same supplier is to be continued the manager informs the head of that department i.e.
either colour or maintenance store regarding this. If the supplier is to be changed he will
himself decide who will be the supplierand at what rate it will be purchased. He mayask for
quotation from new supplier ornegotiate further with the existingsupplier. Finally he informs
the head regarding the changesand finally head orders the supplier on telephone according to
requirement.
Once the order is received, whether bynew or old supplier, quality checking is done to ensure
that the received material is of desired standard. If the order isaccepted then challan issent to
the finance department for bill payment. And if inany case order is rejected,goodsare sent
back to the supplier for replacement.
Inventory Control System:
For any production unit it is very important to maintain stock at the optimum level.
Inventory stockshould not exceed after some extent so as to maintain the working capital
balanced and also it should not be too less to meet production requirement. In Rivaa Exports
they do not keep the inventorylevel for more than 15 daysstock in order to manage working
capital.
Inany dyeing or printing unit inventoriesare the fabric instock whether unprocessed, work
in process or finished fabrics, colour store and maintenance store. It is not an easy job to
controlsuch huge stocksand get it easily on time. In Rivaa Expots various departmentsare
made for thisand there byassign a head who carryall the responsibility regarding various
stocks.
Fabrics
Whengrey enters the factory first step is each roll ofgrey is marked with lot number and
partyname to identify the roll. So it is very difficult that any roll is misplaced. Also, after
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each process there isa particular department where the fabricsare kept after that particular
process.
In textile market, rate of P.O.Y., Yarn,and ultimatelygrey fabrics keeps on fluctuating. So
during recession period what customer does is they purchase huge amount ofgreyand loads
it in the mill, but do not give programme for it. At such situation the place where grey fabrics
are kept is blocked. So what they do is theystart the production processand complete it till
the fa bric is dyed or bleached and pass through stenter. There is special department called
white department at different places in the factory where such half processed fabricsare kept.
These departments are very clean coated with wooden carpet and fabrics are well covered
with plastic covers to keep it dirt free.
Colour store
Colour store is the place where the all the colours and chemicals are kept. There are two
departments of colourstore one where the coloursare actually issued and the other is where it
isstored. When the firm purchases the colours or chemicals it is kept instore only.
There is 1 stockist and 4 helpers working in this department pershift. As coloursare the main
raw material of any printing house their stock must be managed efficiently. Head of this
department and his assistants take care of the stock. They maintain a strong stock register
which is daily updated according to days issue. The coloursare issued onlyafter receiving
receipt signed by the assistant master. This receipt contains detailslike name and quantity of
material.
Also they continuously report to management regarding the position of stock or if some
materialsare required to re orderagain. Theyalso keep eyes on expiry date of each material,
ifsome materials expiry date is comingnearby and it is remain unused such materialsare
returned to the supplier before time so that company can be saved from unexpected loss.
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Maintenance store
In maintenance store spare parts of machines,stationery items, electric equipmentsand other
physical equipment which are required continuouslyare stored. Here also astock register is
prepared where issue or receipt of any item is noted down. From the stock register book
available quantity can be known any time. Here when the material is issued no receipt is
received because it isnot possible to issue receipt forsmall items like pens etc. so forsuch
items they asked for old used item or for expensive item they ask the head of department
where such material is to be used. This method helps the employees to become more careful
regarding materialand ultimately helps the firm from nominallosses.
Different Records Kept In Store:
There are three separate storesat Rivaa Expotrs Ltd.
y Colour/chemicalstorey Maintenance storey Finished goodsstore
The major function of the stores is:
y Receipt of materialsy Storage & maintenance of materialsy Issue of materials
Each store hasa manager who regulates the working of the store. Followingare the records
kept by the store manager:
Material Inward Register:
Informationabout the material received, its quantity, time of receipt, itssupplier is recorded
in this register.
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Item wise stock register:
Opening balances, closing balances, issue, receipt, wastage, etc of different items kept in
store are recorded separately in the stock registers.
Inspection reports:
The quality, quantity of different items in store is checked & recorded in the inspection
reports.
Purchase Indents register:
The items required by the store department are requested from the purchase department
through the purchase indents.
Material issues register:
Informationas to what material is issued to which department & their quantities, purpose are
recorded in this register.
Gate-pass register:
When finished goodsare dispatched to the customers,gate pass is prepared & is maintained
in the gate pass register. Gate pass isalso knownas invoice.
Pending purchase order book:
This register includes informationabout all the pending orders with the suppliers.
Types And Classes OfMaterial-Handling Equipments:
Material handling is defined as controlled movements of materials, from receipt through
storage & production and up to shipment of finished products. A proper material handling
system ensures proper movement of raw material,spare parts, work in process inventory, by
products, waste materials, finished goods from one location to another within the factory
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premises. It also covers the storage of materials in the factory premises. The external
movement of materials is covered under the discipline called logistics.
Rivaa Exports uses manual as well as semi manual material handling equipment for the
movement & storage of materials.
They use the following equipments for movement of materials:
Trolleys Rollers Lorries Pipelines Handcarts
They use the following equipment forstoring the materials:
Steel racks Cupboards Barrels & Tanks
There are different types of equipments used to move & store different types of material. The
classification of the various handling equipment are as follows:
As per form of material:
Trolleys, rollers, Lorries, Handcarts, Racks & Cupboards for cloth & spare parts. Pipes, barrels, tanks for water,acids, chemicals & dyeing colour. Pipelines & cylinders forgas & steam.
As per path of movement:
Handcarts,lorries, trolleys for movement ina variable path. Pipelines for fixed movement. ( vertical or horizontal)
As per degree of automation:
Rollersare semi automatic equipment. Hand carts, Lorries & trolleysare manual equipment.
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As per the purpose:
Racks & cupboards are used for the storage of spare parts, electronic items,stationery items etc.
Cylinders forstorage ofgas. Barrels & tanks forstorage of chemicals, dyes,acids, water etc.
As per the destination of transportation:
Trolleys, Lorries & handcarts are used to move semi-finished material or finishedmaterial from one department to other department within factory premises.
Classification OfInventories According To Abc Analysis And Ved
Analysis:
Any company has to keep substantial levels of inventories of all types to ensure that the
business processes are carried out in a effective way. But controlling all inventories
simultaneously is very difficult. Hence, the inventoriesare divided into many classes,so that
each division is properly administered. There are many different classification theories
develop like ABC analysis, VED analysis, FSN analysis, etc.
Rivaa Exports is basically dyeing house. It isa huge unit & it keeps large inventories ofall
the items, as it cannot afford production loss. Inventories at Rivaa Exports include dyes,
chemical, colours,spare parts, electric fittings,lubricants & oil, etc.
Classification as per ABC analysis:-
It is properly knownas Always Better Control. According to thisapproach there should be
a differential treatment for various classes of inventories on the basis of its monetary value.
This monetary value is consumption value of various products. In most inventoriesasmall
proportion of item accounts fora very substantial usage whereas large proportion of items
accounts fora very small usage. ABC analysis based on the empirical reality,advocatesa
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selective approach to inventories into 3 classes according to the descending order of
consumption value of items.
class
% of
consumption
% no. of
items
A 65% 15%
B 25% 25%
C 10% 60%
Classification of inventories as per ABC analysis is as under:
Disperse dyes are main dyes used; dyeing chemicals like soda ash, caustic, K-T,formic acid, hydrochloric acid, M.C.L., etc; finishing chemicals like fibrocil, ciba
soft, C.M.H, etc & other chemicals like citric acid, liozen, soaps, etc are major
chemicals used & other itemslike fuel ( lignite, coal,gas) & electric fittings, bearings
are put in A class & their purchases are highly procedural. They are purchased
from more than one supplier. Their inventoriesare not allowed to increase overaset
level. A class of itemsare those items who contributes 65% in consumption value.
Dyes like cationic dyes, pigmentsare used at a lower level, washing chemicals likehydro caustic,acidic acid, soaps, etc; general chemicals like poly thread, sodaash,
M.T, H.T, etc are used relatively at lower level. Other items like bolting cloth are
placed in B class. Spare parts of machines are also placed in B class. These are
those items who contribute 25% in terms of no. of items & there value wise
contribution isalso 25%.
Whereas water, coal, few lubricants & oils, valves, V-belts, pipe fittingsare placed inC class. It has 60% ofno. of items but their value wise contribution is only 10%.
Now here at Rivaa Exports, water & coal is the main item which is used in the production
process. Without them the production isnot possible. Since both of these itemsare available
at very cheap rates & hence they are placed in C class, but it is very important from
consumption point of view. So we can use another classification to divide the inventories
properly.
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Classification As Per VED Analysis:-
According to VED analysis the inventoriesare classified into 3 classes called Vital (V),
Essential (E), Desirable (D) items.
Following is the classification of inventoriesaccording to VED analysis:
y Vital items:- Theyare those items without which production willstop instantly. Theyare disperse dyes, finishing & dyeing chemicals, water, coal, diesel, fuels, etc are
considered as vital items.
y Essential Items:- They are those items without which production may not stopinstantly but there can be problems like slow down of production. Theyare bolting
cloth, washing chemicals, cationic dyes,gums,lubricants; pigments, etc are essential
items.
y Desirable Items:- No itemsare generally placed in the desirable categories,as theyare omitted & alternate usesare developed out of essential items.
Maintenance Planning System:
Maintenance planning is very important part forany production unit. Forany production unit
production loss due to breakdown of machines is veryshameful part. It isnecessary that all
machineriesare taken well care and serviced regularly in proper manner. In Rivaa engineers
give enough importance to maintenance planning which ultimately increasess the life and
resale value of machineries.
In Rivaa there is a special team of engineers and their assistant who handles all activities
regarding maintenance. These engineers are very efficient and have a vast knowledge
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regarding the machineriesand their parts. There are two teams of engineers havingseparate
workstation, one for dyeing machineriesand other for machineries related to printing.
While maintenance work the machineries is to be shut closed, so time planning for
maintenance isalso important. It should be seen that there should be minimum production
loss due to maintenance. There is one day off every week for maintenance purpose. On
Saturdaystaggering occursso maintenance day is kept on that day.
In Rivaa the system for maintenance is very logicaland efficient. There isa register in the
workstationarea where anyone can write the complaint or problem regarding machine in it.
So operator orassistant operator of machines writes their evensmall problem in that register.
Then the engineersstudy it continuouslyand plan his maintenance work. If he cansolve the
problem immediately without interfering in production process, he solves it at the same time.
If the work is very complicated or time consuming he solves it on the day ofstaggering.
Beside this engineers have their fixed routine workalso during which they do routine services
and check up of each machines whether any problem is registered or not. During the
production process, emergency occurs due the breakdown of the machinery that is to be
repaired immediately otherwise can result into huge production loss, at such time the
maintenance department playsan important role.
Records Related To Production Operations At Different Machines:
Beinga production unit Rivaas mainaim is to earn high production. For huge production
capacity it is not easy to maintain records related to production operations. But it is to be
maintained in order to control production capacity, cost and ultimately profit of the firm.
It is very important in the cut-throat competition to provide competitive price to the
customers, for this it is necessary to control cost of production which is possible only by
maintaining records related to competition. Here managers have designed various for
different machines from which easily all the required information can be known regarding
units of production, time taken by it, time duration of machine not operated and reasons for it.
For every machine different report is designed which isshown below.
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All this reports are prepared by the supervisor or assistant master on daily basis, and is
checked by managersand director of company. Actual production can be known from this
documentsand production capacity can be controlled. Forany queries directors consult with
masterand try to solve the problem.
The format of the various reports generated is as follows :
1. DRUM:
SR NO. DRUM
NO.
PIECES QUALITY REMARKS TIME
IN
TIME
OUT
REPORT:
REPORT:INCLUDES REASON FOR PROBLEM OR BREAKDOWN ON
MACHINE.
By preparing this report one comes to know when and how many batches of grey are
processed. It also includes the reason forany time delay or time gap between two batchesso
that if there anyserious problem then the manager can take any beneficialstep for betterment.
2. JET MACHINE:
SR.
NO.
QUALITY PROCESS PIECES METERS TIME
IN
TIME
OUT
REMARKS
REPORT:INCLUDES REASON FOR PROBLEM OR BREAKDOWN ON
MACHINE.
REPORT :
REPORT :
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3. STENTER :
STENTAR NAME: SUPRA
SETTING
FOR PRINT
DRY FOR
PRINT
SETTING
FOR DYED
FINISH
PRINTED
FINISH
DYED
FINISH
REPORT:INCLUDES REASON FOR PROBLEM OR BREAKDOWN ON
MACHINE.
This report helpsalot to find out how many meters of printed or dyed are getting finished or
setting is done. It helps to know that in how many hours what metersare getting produced
and what should be the speed ofstentar to increase production.
REPORT :
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orsupervisor if they want drumming effect or not. But in certain quality of fabrics it is
necessary for better feeland flow.
Drum machine is the large structure like a watergeezer. It is horizontal cylindricalshaped
equipment consist ofstrong rectangular box inside. In drum machine the cloth is put for 6
hours, 2.5 kg pressure isgiven in the machine and the temperature of water in machine is
130 centigrade. The steam pressure comes from boiler. It automatically releases steam
when the pressure is very high in the machine like pressure cooker. The other purpose of
drum machine is to reduce the weight of the cloth. Caustic and various swellingagent,
stain remover is the chemical to which the task is done.
The total production of the drumming machines isapprox 35000 per day.
4.Jet Machine:
Grey cloth is manufactured by weaverand sold to different partiesafter that it reaches to
factory, between the two tasks there are lots of procedure, which have to carry out and in
those procedures the cloth,gets dirty. There are so manystainsand different types ofspots
and other chemicaland physical imparities on the cloth. So Jet machine removesall the
dirtiness of the cloth and converts the color in to optical white which is knownscouring
process. And then clothesare dyed in the same machine. Different dyesand chemicalsare
used for this process. Also the main work of jet machine is weight reduction. It removes
the oil from the grey which is to be put while weaving the grey.
Jet dyeing machine is long and cylindrical sha pe. There is U sha pe jets dyeing
machines. There isalevel recordinggauge just near the bottom of machine which records
the level ofliquorspeed. In Rivaa Exports Pvt. Ltd there are 14 jet machinesand theyall
are continuously performing the work on daily bases. In jet machines temperature is kept
between the 80 and 130 C and the pressure is kept between 2 3 kg.
The process time is 6 hoursand during each process 24 to 48 rollsare processed depends
upon the size of machine (i.e. capacity for big machines it is 180 kgs, 100-110 kgs for
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small machines) and programme of master. In jet dyeing machine the cloth is dyed inall
dark or light colorshades but as majority of fabrics comes for printing purpose most of
the fabrics is made white in colour, as white is the best base colour in printing. The
chemical used depends upon features of fabrics. For different fabrics different chemicals
in different quantity is used. Jet machine is the central machine in dyeing process house.
In order to achieve good dyeing result normally four types of energiesare utilized:
y Chemical i.e. the dyestuff which is required a chemical for dyeing.y Thermal i.e. high temperature.y Fluid energy i/e/ circulation ofliquor.y Kinetic energy i/e/ rotation of material.
Detailed process of jet dyeing isshown below:
1. Loading: In this process Jet Dyeing machine is filled up with waterand thereafter thecloth is in jected into the machine and finally the two ends of cloth are tied up and
machine lid is closed.
2. Washing: In this process the cloth inside the jet-dyeing machine is washed with coldwater. There are basically two processesadopted for the washing.
a) Running wash: In this process the fresh water is in jected from the top of jet dyeingmachine and isallowed to throw out from bottom fora period of 15 to 20 mins. In this
process mainly the impurities present on the cloth surface is removed.
b) Batch washing: In this process the cloth is washed with water filled in the jet-dyingmachine for period of 5-10 minutesand this water is removed. Again the jet-dyeing
machine is filled with waterand washing is done. This process consumesless quantity
of water.
3. Scouring: In this process hot alkaline liquor is circulated under pressure of 2-3 kgs for30-45 minutes. At thisstage the temperature is maintained up to 130C. In thisstep
solventsare removed from the fabric and weight reduction takes place. The chemicals
added in this process are like Hydro sulphide, caustic soda, deformers etc. After
scouring thisliquor from the machine is drained out and again running wash is done.
4. Washing: Same processas instep 2 is repeated.
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5. Acid wash: In thisacid isadded along with waterand steam is introduced inside thejet achieving temperature up to 100C. At this temperature cloth is kept a bout 15
minutes and thereafter the wastewater from the jet-dyeing machine is discharged.
After this process the cloth is ready for dyeing.
6. Dyeing: In thisstep dye of required colorsare added in the jet dyeing machine withfresh water along with other chemicals like leveling agents, deformers, swelling
agents,softeningagents, dispersingagents etc. This mixture is then heated up to 105-
130C and this temperature is maintained constant up to 15-30 minutes. This batch is
then cooled up to the temperature of 90C and thereafter discharged.
7. Washing: After dyeing operation, the cloth is washed same asstep no 2.8. Acid wash: same as point no. 5.9. Unloading: The cloth is removed from jet dyeing machine for transferring to the heat-
setting machine.
The total output ofall the jet machines isaround 55000-60000 meters per day.
5. Stenter:The purpose for which cloth is put in the stenter issettingand finishing of fabrics. In other
words, ironing of fabrics. The stenter machine is the main machine of a firm carrying
dyingand printing processes. The grey is laid in the sheet from over the roller into the
machine. The width of the grey is controlled bya photocell in the machine. The grey is
dried by high oil temperature ofabout 180-210 degree Celsius. The shortage of the grey
cloth is reduced so that the coloring may be done uniformlyand the grey properlyabsorbs
it.
Thus the basic purpose ofstenter is better finish, width settingand forsoftness. Before the
fa bric is pass through the stenter it pass from a open bucket which contains water and
certain chemicalslike amino Silicon for hard finish. After this, it passes from mangle,an
important part of stenter which squeeze water and chemical from which the fa bric just
passed then it goes through chudi roll, a heavy roller which stretches the cloth for
temporary removal of curls then it passes through chambers ofstenter for heat setting. Just
before it enters in the chamber there is a transitory photo cell which automatic set the
width of the cloth according to programme set by the operator.
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A stenter processes 80,000 meters of cloth daily for the firm. The grey after being
processed in the stenter machines is set for printing. In certain cases the parties order
only for dying, for them the final product is ready. .
There are 2 stenters in Rivaa Exports Pvt. Ltd. both of which are of 4 chambers. For best
utilization of the resources and equipment and to reduce the cost per unit at this
competitive edge, machinesshould be used at there maximum capacity.
6. Printing Machines
Printing process has to carried out with following 4 steps
y Preparation of designand deciding colour combinationy Preparation ofscreeny Preparation of coloursy Printing of fabrics
Preparation Of Design And Colour Combination:
Printing process starts with the preparation of designs that are going to be printed on the
fabric. Designingnowadays have become the most important and the vital part of the fabric.
It is through designs only the masterapproves from the buyeraftershowing the whole range
of collection that he hasnewly developed and thus receives order. The designsare the heart
of fabric, so the master has a team of 6-7 designers under him, which includes both hand
artistsas wellas computer designers. The designing includes two types of designers:
1. Hand artists.2. Computer designers.
Before one decade, there were no computersso the designs were prepared by the artists with
their hand which was very time consuming and then it was replaced by computers which
made designing verysimpler. But now also there are some designs, which cannot be made as
sharp as the design made through computers.
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In this company, there are 3-4 hand artists. They make new designs everydayaccording to the
trend or any particular order after guidance from master. They also create by their own
imagination but finally the masterapproves them. They draw ona Kodak paper then theyare
traced or exposed through ultraviolet rays/lights on a big Kodak paper. After this they are
sent to the photography department who then transfers the design from that pa per to the
screen that is made of rectangularshaped closed rod, which is covered by bolting cloth. Then
after it is prepared then it goes to printing department. But sometimes these hand made
designs are also scanned into the computer and then it is edited and then finally sent for
screen preparation department.
Apart from hand artists there are 3/4 computer designers, who make new designs on
computer through software called Photoshop. The new designs are prepared by them but
nowadays the master buy sketches of designs from professional designers who regularly
develop new designs according to the prevailing fashion in the city. These designs are the
scanned by the designers and edited if needed then they are transferred to the screening
department for exposing of designs.
Screen Preparation:
After the designing process has been done, it is then transferred to the screening department.
Here screen is prepared in two ways:
y Photographyy Engraving machine
1) Photography:Ultraviolet rays transfer the design from that Kodak pa per to the screen, which is
made of rectangularshaped closed rod that isattached by bolting cloth on which the
blue chemicalnamed 999 isapplied before transferring the design. Then the next step
is that the screen is then exposed and then issent to the sampling for final testing on
the sample fabric. Ifapproved then it is passed to the printing machine.
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2) Engraving machine:
This machine has been replaced the photography process to make screens. This
machine was imported from Japans best company making textile machineries. The
machine is called ICHINOES MACHINE.This machine has the capacity to make 50-
80 screens in 24hrs. This is one kind of printing machine only. At first whenscreens
are prepared 999 chemicals isapplied on it. The next step is to print the design on the
screen with the hel p of machine. Then the screen is exposed on the table under
ultraviolet lights for 30 seconds. Lastly, the screen is kept in water for 20 minutes
after which it is kept undersunlight for final touch up.
Preparation Of Colours:
While finalizing the designs master also decide various colour combination of particular
design and accordingly informs his assistant regarding proportion of colours. Colours are
prepared in the colour kitchen,now the raw material for these coloursare same which can be
used in jet machines but finally those coloursare not used while printing. Coloursalso pass
through some process, in this process coloursare mixed with hot treated gum, which is very
thick and then kept it idle until it reaches room temperature. Here it very necessary to
maintain proper proportion of colours while mixing. The colours are now ready to use for
printing.
Printing Fabrics On Flat Belt Machine:
Now after the design,screenand coloursare prepared before printing workstarts fabricsare
passed through batchingstenter. Batchingstenter islike stenter only ofsingle chamber but at
last fabricsare rolled tightly over beam rod. This rod is kept just before the flat belt machine.
Flat belt consist of circular flat rubber belt, which movesaftergap of 5 seconds. On this belt
screens are kept which has normally 1-meter width. On most of the machines 10 to 12
screens can be kept i.e. 10 to 12 colour design can be made onsingle ongoing fabrics.
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According to designsscreenare kept on belt with support. Fabric is introduced through these
screens over the blanket. As the fabric is brought underascreen the screen is moved over the
cloth. The colorand design on the screen in thus obtained on the fabric and fa bric moves
ahead fornext screenand the processgoes on till the last screen comes. As the cloth passes
through the screens workersstanding by pulls the puller over the screenso that the marked
design prints on that part of cloth with one particular color. At the end afterall the screensare
used the cloth is passed through the dryer where the wet coloursare temporarily dried so that
different colours doesnot mixes with each other. The temperature of this dryer isaround 150
degree centigrade. After this process the coloursare required to permanently fixed for which
fixation process is explained further.
A printing machine printsapprox 10000 12000 meters per day.
7. Padding machine
In the locallanguage this type of dyeing is knownas padding process but actually it isnamed
as PAD DYEING. In this machine the grey is dyed. The same can be done in jet also but the
difference is that here two or more shades can be dyed in jet only single colour is dyed
uniformly but here onasame fabric 2 to 4 shades can be dyed. The process before and after
pad dyeing is same as the process before and after printing machine. For padding grey is
passed through batching stenter after it is bleached and finished properly. This process is
basically a hand process, a man continuously pours colours on the pad, which are thick
enough to merge each other,and other person spread the colours to the fabric to dye. This
person is very talented and professional and they are highest paid workers in the whole
factory. The quality of this process fully depends upon his capabilities. Like printingafter this
also fabricsare required to pass through fixation process, which is explained further.
The total production ofa padding machine isaround 13000 meters per day.
8. Fixation process
The purpose of fixation is to fix the colours permanently. The fabric after print or pad dyeing
passes through two processes for fixation of colours.
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y Loop agery Washing
Loop ager
After the cloth is dried in the dryer the cloth is taken near the loop machine, which is
collected, in the dry trolley. The main purpose of loop machine is to fix the colour and
remove the unwanted colour from the printed cloth. Loop machine is big rectangular box
where there is high temperature steam around 165 degree to 170 degree centigrade. It takes
one and half hour to generate such hot steam. Fabric is passed through this box slowly which
fixes the colours. At any time inside the box there is 250 to 300 meters cloth.
Total output of this machine isaround 24000-28000 per day.
Washing
The cloth is washed finallyafterall the above process for removing unfixed colourand other
impurities. For washing the fabric is passed through 10 tubs of water, which inlocallanguage
said as kundis. The descriptions of these kundisare given below.
y In the first three tubs there is cold water containingsoap. Here the unfixed colour isremoved from the cloth.
y In the next three tubs contains hot water with hydro caustic for the removal ofgumand other impurities.
y The next three tubs containacetic acid for bettersoftness in fabric.y And in the last tub plain water for removingall these chemicals.
After the fa bric is completely washed the wet cloth is put in the small machine to squeeze
cloth. These machinesare called hydro extractor. Now the fabric is ready for final finish. The
fabric then once again passes through stenter for finish and then through 0/0 machine forsoft
feel.
9. Zero Zero Machine :This machine is basically used for ironing the cloth before taking it to the packingand folding
department. After the cloth is passed to the zero zero machines the feel of the cloth
improvesand givesa betterlook.
A machine givesa production of 20000-22000 meters per day.
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10.Folding Machine
In Rivaa Exports Pvt. Ltd. there are 12 folding machines. This machine arranges the Grey
from rough form to unique form. It requires the cloth to be folded and packed properly in
order to carryand store easilyand efficiently. It converts the scattered fabric into folded roll
or taka. After the fa bric is folded the meter man counts the meter of each roll and note it
down on job card issued by excise department,also the finish meter is written down on the
rollas well. All the rollsare stored according to its roll in the finish department. These lots
are now ready to dispatch to its real owner. Capacities ofall folding machines are 60000
meters per day. Thus,after folding theyare delivered the next day to the customers.
ListOfPlant & Machineries:
Sr.
No.
Name of Machinery No. of
Machin
es
USE
1. Stenter Machines (Total 8 Chambers) 2 WIDTH SETTING,IRONNING & FINISH
2. Printing Machines (Automatic with 12 printable
color)
3 PRINTING FABRIC
Printing Machines (Semi Automatic with 12
printable color)
2 PRINTING FABRIC
Printing Machines (Semi Automatic with 17
printable color)
2 PRINTING FABRIC
3. Rotary Printing Machine 1 PRINTING FABRIC
(CONTINUOUS SINGLE
PRINT)
4. Jet Dyeing Machine of 250 kgs 6 SCOURING/DYEING
5. Jet Dyeing Machine of 80 kgs 6 SCOURING/DYEING
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6. Jet Dyeing Machine (long tube) of 300kgs 2 SCOURING/DYEING
7. Boiler (Coal fired) each of 5 ton/hr. 1 STEAM GENERATION
8. Universal Loop Steamer 2 STEAM FOR COLOUR
FASTNESS
9. Batching Machines 1 BATCHING
10. Drum Washer Machines of 300kgs 3 TO OPEN YARN
(MAKE GREY READY FOR
PROCESS)
11. Drum Washer Machines of 100 kgs 2 TO OPEN YARN
(MAKE GREY READY FOR
PROCESS)
12. Folding Machines 4 FOLDING OF FINISHED
FABRIC
13. Padding Machines 2 DYEING IN STRIPE FORM
14. Zero Zero Machines 2 SOFTNESS
15. Ager Machine 1 STEAM FOR COLOUR
FASTNESS
16. Diesel Generator Machines 4 POWER GENERATION
17. Compressors 6 AIR PRESSURE
18. Flatbed Screen Engraving Machine 1 CREATE DESIGNS
19. Delivery Vans 3 FOR PICK AND SEND OF
GREY N FINISHED GOODS