ABOUT COMPANY Alok Industries Ltd is one of the Indias largest Vertically Integrated Company. It is headquartered in Mumbai with its manufacturing units in Vapi, Silvassa &Navi Mumbai. The company is an end to end provider of integrated textile solutions with five core divisions: - Cotton yarn, Polyester yarns, Apparel fabrics, Home textiles, and Garment.HistoryAlok was established in 12th March 1986 as a private limited company with first polyester texturizing plant being set up in 1989.The name of the company was changed to Alok Textiles Industries Private Limited on 17th November 1992 and converted into Public Limited Company on 11th February 1993.In the year of 1996 Alok industries started knitting division in silvassa. Alok industries have expanded into weaving, processing, home textiles and garments. Alok industries have integrated backward into cotton spinning and manufacturing partially oriented yarn through the continuous polymerization route. Alok industries also provide embroidered products through Grabal Alok Impex Ltd., our associate company.In the year of 2007 Alok Industries entered into the domestic retailing business under the name Homes & Apparel that is H & A.In the year 2008 Aok Industries as IMS that is Integrated Management System.Alok Industries then further stepped for continuous polymerization in the year 2009 and in 2011 polyester staple fibre.Alok Industries has an international presence in retail segment through its associate concern, Grabal Alok (UK) Limited.Alok is an end-to end textile solutions provider. Its products encompasses the entire value chain from cotton and blended yarn to fabric to garments and home textiles. A significant portion of these product are cotton based- manufactured from both organic cotton and regular cotton; blended and polyester yarn offerings also form part of Alok portfolio of products.

ALOK INDUSTRIES COMPANY PROFILE: Founder Chairman: Bhagirathaml Jiwarajka. Chairman: Ashok B.Jiwarajka. Managing Director: Dilip B. Jiwaraka General Managing Director: Surender B. Jiwarka.

ALOK INDUSTRIES TEXTILE PLANTS

MUMBAI HEAD OFFICE , GARMENT DIVISIONDAMAN GARMENTSVAPI DYEING & PRINTINGSILVASSA SPINNING, WEAVINGTEXTURISING

Alok industries competitors:- Arvind mills Reliance Bombay dyeing Creative garments Certification to Alok industries:- ISO 9001 : 2008 (Quality Management System) ISO 14001 : 2004 (Environmental Management System) OHSAS 18001 : 2007 (Occupational Health and Safety Management System) SA 8000 : 2008 (Social Accountability / Social compliance )

Aloks vision :- To be the worlds best integrated textile solutions enterprise with leadership position across products and markets, exceeding customer & stakeholder expectation.Aloks mission :- Be a knowledge leader and an innovator in our business. Maximize people development initiatives. Optimize use of all resources. Become a process driven organization Exceed compliances and global quality standards Actively explore potential markets & products Offer innovative, customized and value added services to our customers Be an ethical transparent and responsible global organization.

VALUES OF THE ORGANIZATIONCustomer SatisfactionAlok will be attuned to market needs; wherever possible, It anticipates market needs; It respond quickly to changes in customer requirements. It completely focused on quality. It keeps delivery commitments on time and every time. It develops new products and processes that go beyond customer satisfaction to achieve customer delight.Passionate About ExcellenceExcellence is non-negotiable in every aspect of their business process. Superior quality of performance is critical to their business growth and success. They constantly strive to exceed expectations: be it internal or external.

Developed Human CapitalThey empowers, energise and inspire their people to perform beyond their best; they will create empowered teams that take informed decisions; they recognize and leverage skills and strengths of various teams; they enable sharing of knowledge; they creates an adequate 'bench strength' that takes care of changes in business scenarios.Fair To AllAll their actions are determined by fairness; they are fair to their customers, vendors, shareholders, all their business partners and society at large. Fairness is not just sticking to the letter of the law or the contract but appreciating its spirit and basing all their actions on being fair to the spirit of that understanding.Concern for the Environment and the CommunityThey takes the utmost care of their environment and the communities in which they operate; they nurture their environment and its natural resources and ensure that none of their actions deplete or pollute them; they encourage initiatives that create environmental sustainability and help in community development.Safety and HealthThey provide a safe workplace. They promote the health and well-being of their people and their families. They encourage healthy work habits and a 'work-life' balance. They believe that working safely and protecting the health of their people is 'working smart' and creates greater and more sustainable wealth.Responsible Corporate CitizenThey recognize that they have their responsibilities towards the society in which they operate. They commit their selves to be a responsible corporate citizen; their activities should not only create shareholder wealth, but also community wealth.

2.Fire and Safety DepartmentThis department provides training to new workers and at the same time assuring healthy working environment to the employee. This department works under the standards of OHSAS18001 (Occupational health and safety management system).

In order to promote uniform standards in health, safety and environment (HSE), every company has developed tools for establishing, auditing and monitoring the industry.

Fire department have their sprinklers, monitors, pump house etc. installed in the industry to ensure that fire doesnt harm any personnel. There are two different types of fire extinguisher used by departmentPortable extinguisher (Trucks, fire extinguisher cans etc.)Fixed extinguisher (Sprinklers, pump house etc.)There can be different causes of fire in industry thats why fire are classified into 4 different class.Class A:- Class A Fires consist of ordinary combustibles such as wood, paper, trash or anything else that leaves an ash. Water works best to extinguish a Class A fire.Class B: Class B Fires are fueled by flammable or combustible liquids, which include oil, gasoline, and other similar materials. Smothering effects which deplete the oxygen supply work best to extinguish Class B fires.Class C: Class C Fires. Energized Electrical Fires are known as Class C fires. Always de-energize the circuit then use a non-conductive extinguishing agent. Such as Carbon dioxide.Types of fire

Class D: Class D Fires are combustible metal fires. Magnesium and Titanium are the most common types of metal fires. Once a metal ignites do not use water in an attempt to extinguish it. Only use a Dry Powder extinguishing agent. Dry powder agents work by smothering and heat absorption.

In Alok, for immediate help, there is Manual Call Points (MCP) fitted. They are of two types. One has push buttons that we are supposed to press if any fire occurs. Another one is break glass". They are used to allow building occupants to signal that a fire or other emergency exists within the building. Under normal conditions push button will be in the depressed condition. In the case of fire when the glass cover is broken, the push button will be released by the spring action and will actuate an alarm at the control panel through its switching contacts. In addition to this, there will be an LED indicator on the monitor module for visual indication to locate the call point easily.There are also smoke sensors which detect the smoke immediately and as soon as it senses the smoke, water is sprinkled by the device. There are total 6 private fire vans that Alok owns. Two of them are Mercedes foam tender and foam nurser,

Fire department uses different method for different class of fire.Cooling:- Class ASmoothening & covering:- Class BStarvation method etc.

Safety department works over a guideline detailing the requirements which allow suppliers to comply with the company Standards of Engagement (SoE). The guidelines described do not necessarily reflect the national laws of all countries where suppliers are based, and it is responsibility of individual suppliers to ensure that they meet all legal requirements relating to health, safety and environmental matters.

2. RAW MATERIAL DEPARTMENT 2.1 Grey yarn store room In this inventory grey yarns are stored that comes from either alok spinning unit or from different spinning mill from all over india.Process Flow of department:-a. PPC is developed by PPC department.b. Booking of Material is done by Head Office in Mumbaic. Material comes by truck to the industry.d. Department sends some of the sample to Quality Assurance Department for quality check from the truck.e. If material are not of acceptable quality then they are returned to the manufacturer.

f. If materials are accepted quality then they are allotted a position in store room by department.g. Unloading is done and materials are placed on its position.h. According to the order from weaving department raw material are dispatched from store room to other department.

Storage capacity of store room :- 1200 ton Average weight of a cone :- 2.5 kg Raw material generally comes in two form in alok:- Conical form Chesse form

2.2 Dyed yarn store room In this inventory grey yarns are stored that comes from either alok spinning unit or from different spinning mill from all over india. Process flow of this inventory is also same as grey yarn inventory. Storage capacity of the store room :- 250 ton Weight of the cone depends on the order placed.

Different Material, Type and Blends of yarn available in alok :YARN MATERIALBLENDED YARNYARN TYPE

Organic CottonCotton Viscous (CV)Carded Yarn

CottonPolyester Viscous (PV)Combed Yarn

PolyesterPolyester Cotton (PC)Compact Yarn

ViscousChief Value Cotton (CVC)Core/Fancy/Lycra

High Twist Yarn

Roto/Open End Yarn

Slub Yarn

PPC (Production Planning Control Department)PPC is an activity that is performed before the actual production process takes place. The main role of this department is that it communicates between markets and production. After receiving enquiry from market the commitment of delivery date is given. PPC also determines the cost which depends mainly on the EPI and PPI.Objectives of Production Planning Control: To plan production facilities in the best possible manner along with the proper systematic planning of production activities. Providing men, machines, materials etc. of right quality, quantity and also providing them at the right time forms a very important factor. To inform, about the difficulties or the various awkward positions expected to crop up later, to the management before hand.Working Procedure: Desk Loom (for color matching) Sample Proto Sample (for garment look) Sales Man Sample (fabric look, type of garment) Bulk Sort creation Unique identification code is given to the order with this number the order is identified throughout the process Costing Inquiry (Date of Grey delivery & Finish delivery) Sales order (Legal Agreement of Order) STPO (Stock Transfer Purchase Order) The final order detail is send to Mumbai and from there it is send to all the departments. It includes all the wastages and shrinkage during the process. Designing Pattern Paper (for Loom) Production Order (In PPC) This production order is sent to all the departments like raw material, preparatory, loom shed.

4. QUALITY ASSURANCE DEPARTMENT. 4.1 Role of department QA department are responsible for the testing and the acceptance of raw material that comes from different places. Different parameters that are checked in raw material (yarns) :- Yarn strength Yarn imperfection Yarn count TPI Analyses the specimen that come from buyer. Parameter analyzed are :- Warp count Weft count Types of material(In warp and weft) Weave Analyses working condition of worker and machine. Audit the machines. Checking of machines for Oil leakage. Air leakage (Air jet machines). Missing parts of machine. Width of cutting waste Analyses weaved fabric for defects. Follows 4-point inspection system. Defects in weaved fabric :- Unevenness Broken end Reed marks Broken pattern Double peek Loose warp etc. In folding department QA do grading of fabric.

4.2 Test conduct in QA department For testing of yarns first of all lot of yarns are formed. Plan for lot formation :-Lot sizeNo of conesNo of lot to prepareTotal no of lot formed

Above 4000 kg1515*115

Above 1000 kg to 4000 kg1010*110

100 kg to 1000 kg55*210

Less than 100 kg52*510

DesigningThe objective of this department is to prepare a pattern for the weaving process to achieve the desired effect and look on the fabric as per buyers specification. The department receives the specifications from PPC department after sampling is done and samples are send for approval, approved designs then go further for production. The departments perform the following work:- Designing the product Analysis & feasibility of product Preparation of bill of materials required for preparing the productStep by step process explained below. Sample of fabric is issued from the HO as per customer requirement. Analysis of the sample is done. Its EPI (Ends per Inch), PPI (Picks per Inch) are calculated and type of weave is determined. Then the report along with sample is sent to QA (Quality Assurance) for further analysis. Specification sheet is then prepared by the Design department after getting report from QA which has details such as warp, weft, reed, width, pick, etc. The process was previously manual which has now been computerized. Handloom sample along with drawing plan is then prepared which is sent to the HO (Head Office) which then approved by customer by sales department. After approval then it is sent to the PPC department along with order details and the PPC department does further procedure of sizing and weaving. Then sample of fabric is again sent to design department for approval.

WarpingThe parallel winding of warp end from many winding package (cone) on to a common package (warp beam) is called warping.Importance of Warping: Construction of a beam of warp yarn. Construction of a parallel yarn sheet. Modifying the faults of yarn like thick or thin place Winding the pre- determined length of yarn. Combination of small packages. Accelerating the next process.

There are 2 types of warping used in industry:-

Direct warpingThe cones are placed on the creels and the ends are passed through two pre stationary rod out of which one is stationary and is movable. These rods are responsible to give proper tension to the yarn. There is also an auto ply tension unit with light indicator to control tension during running and stops the machine. The yarn are passed through a zig -zag yarn guides (dents) to the gear controlled cylindrical beam which continuously rotates and prepares the warping beam. There is also a display at the front of operator which indicates the breakage cone row and column number. Presser roller which is in contact with beam ensures uniformity in formation of the warp beam an in cylindrical from. Singles yarns are preferred for direct warping, as they are to be sized in the successive process.There are total 10 direct warping machines in the industry.8 Benniger Direct warping2 Prashant gammatex These machines have different creel capacity:-7 machines 1088 creel capacity2 machines 680 creel capacity (machine no. 9 & 10)1 machines 630 creel capacity (machine no. 8)Average speed of these machines is 600 rpm

Sectional warpingSectional warping is done in some versatile intricate and majorly yarn dyed pieces where the consumption of different warp yarns is different depending on the design. The drum roller intermittently winds the yarns from creels and the beam automatically moves laterally to get a uniform wound section beam as par the data fed according to the required design. This section warpers beam is then waxed by a winding roller in a continuous manner which successively gets wound on the weavers beam. Double yarns are preferable to be sectional warped. The leasing and section reeds are used to separate different colored yarns and determine number of yarns in a dent respectively.

There are total 12 sectional warping machines.2 Benniger10 Prashant GammatexThese machines have different creel capacity.Machine no. 1&2 = 720Machine no. 4, 5,9,10 = 960Machine no. 12, 7, 6,11,8 = 656

Sizing The sizing process aims at providing extra strength to the warp yarn for withstanding tension and abrasion during weaving. Sizes used are:-1. Adhesives: Modified starch (texoplast), fabric glue, thin volume starch, Potato starch, from corn, wheat, rice, etc., Carboxyl methyl cellulose (CMC), Poly-vinyl alcohol(PVA), Polyester resin (acts as binder).2. Lubricants: Mineral waxes, oils, vegetable waxes and oils, animal fats.3. Additives: Salicylicacid,zincchloride,phenol,emulsifier,softeners,Polyethylene glycol.Sizing machinesSizing processThe warped beams are put on the creels an all the warp ends are passed through various cylinders without any inter yarn entanglement and messing up of yarns.They are passed into a bath of a water base sizing solution. The bath has a temperature of 900c which has nip rollers and two dip rollers which guide the yarn for proper sizing through proper bathing.The yarns have continuous movement through the solution as they travel through the drying cylinders which have temperature of 1400c, 1300c 1250c and 1100c in the respective cylinders in the drying chambers (zone 2 and zone 3).Leasing region is the drying region from where the yarns get separated by dividing rods to avoid yarn group which could create difficulties in weaving.Thus by automatically monitored and controlled system, the yarns are wound on the weavers beam. These weavers beams are transferred to the looms.

AUTO DRAWING IN When drawing in done by automatic machine it called Auto drawing. For auto drawing Staubli Delta 110 machine is usedFeatures of Auto drawing machine:- Manufacturer of the machine is- Staubli. Model is- Delta 110. Maximum speed- 140 ends/min. Up to 20 heald frames can be applied. Both type of drop pins i.e. open and closed type can be used. Both type of heald wires i.e. C & J type can be used. Selection needle is used to select a single end at a time. Selection needle is used as per the count. It has double end monitoring function i.e. it can detect the selection of double ends in the machine. In double end case, the ends are separated & the extra end is fed to an empty drop pin & heald wire which is kept as extra for such an occurrence so that the yarn can be used for weaving the fabric and doesnt become waste. The drawback of this system is crossing of yarns take place, so there is a possibility of end breakages.

Requirements for Auto drawing are:-1. Program (from PPC/Weaving)2. Beam (from Sizing/Sectional warping)3. Heald frame & Heald wires (Weaving)4. D-Box/ Drop pins (Weaving)5. Reed (Weaving)

1. ProgramIn the program which is given by the PPC department the following details are given:- Sort No. Beam No. Total no. of Heald frames in body & selvedge Draft Reed count & denting order Warp pattern

2. Beam Beam is sent for auto drawing by the sizing department/ sectional warping dept.Beam card is also sent which gives details like Warp count, total ends, sort no.

3. Heald frame/ Heald wires Source is weaving Steps:- Removal of heald wires from heald frames. Separation of Part 1 & part 2 heald wires Feeding on Staubli Delta4. D-Box/ Drop pins (warp stop motion)The D-Box arrangement is basically used as a warp stop motion. There are serrated bars on which there are drop pins. Each warp end is made to pass over a drop pin. Due to tension the yarn is held tightly enough in between the slot of the drop pin. If a warp end breaks the drop pin falls on the serrated bar & because of electrical contact the machine stops. Usually when a yarn of count above 60 is to be woven into a fabric the heald wire used is of 0.2 mm thickness. & when the yarn count is below 60 is to be woven into a fabric the wire of thickness 0.3 mm is used.

5. Reed Two different type of reeds are used, Profile reed & Plain reed for Air jet and Rapier Looms respectively

WeavingTypes of looms at Alok IndustryOn the basis of weft insertion mechanism: Air jet loom In the air jet loom, a jet of air is projected across the shed forcefully, that takes the filling yarn to the other side i.e. a jet of air is used to propel the weft yarn through the shed at speeds of up to 600 ppm.

Rapier loom The rapier loom is upgrade from shuttle-looms to the world of modern weaving system and shuttle-less weaving. Rapier looms has been designed to replace the old shuttle looms without any major changes to the existing infrastructure

On the basis of shedding mechanism: Cam Cam looms have a design capability of producing simple weaves. Dobby These are more complicated than Cam systems but have higher initial and maintenance costs. Dobby looms have the capability of producing more complicated and sophisticated weaves. Jacquard Jacquard shedding mechanisms are capable of producing large and intricate weave designs that are beyond the scope of dobby shedding mechanisms. In jacquard weaving, it is possible to control every warp yarn individually.

There are also looms on basis of their width i.e. width of the fabric produced. One is normal width and other is wider width machine.

Weaving Process

Sampling

Bulk Production20cm Lap Dip SampleGaiting/KnottingDrawingSizingWarpingAnalysis (EPI, PPI)

Sampling Cutting

Weaving Procedure| Weaving MachinesUNITTOTAL MACHINESWIDTHWEAVEFABRICBRANDPRODUCTION

AirjetRapierTotal

MaintenanceIn Alok Industry maintenance of machineries is done by maintenance department. It is of two types:-1. Preventivea. Cleaning of fluff accumulated in machines as well as oiling of different parts of the machine Is done to prevent wear and tear and for the smooth functioning of the machine.

2. Breakdowna. Providing solution to any kind of problem occurring in the machines and to fix it after the damage.Maintenance department is centralized department. There is unit wise maintenance head. And for 14-15 machines there is one person. The main role of maintenance department is to make schedule of maintenance and follow the schedule. Consumption of oil is:-1. Gear box-1 machines picanol is 2.5 liter/year2. Cambox -1 machines dobby is 7 liter/year

UtilityThis department looks after electrical, electricity, power and compressor (air supply for air jet looms) in Alok industries. Alok Industries get power from Gujrat Electricity Board (GEB). Phase-1Phase-2Total

Airjet(NW)412305717

Rapier(NW)145110255

Airjet(WW)332570902

Total8899851874

The power consumption is 23MW for weaving. Weaving unit requires 2300 unit per hour and also there is 5, 20,000 unit per day uses of power. 1m production requires 1 unit power. Usages of power are:-1. Loom Power-25%2. Humidification Plant-2053. Copmpressor-45%4. Preparatory-5%5. Other-5%Air Consumption:-1. Normal Width-30 CFM 6 bar pressure2. Wider Width- 50 CFM 6 bar pressure3. Phase-1 Compressor- 9000CFMx4, 3000CFMx14. Phase-2 Compressor-9000CFMx4, 12000CFMx1, 5000CFMx1