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INTRODUCTION TO THE INDUSTRIAL TRAINING

INTRODUCTION
In an organization study each and every department in an organization is observed and analyzed in detail. The study gives equal importance to every organ of an organization and projects their importance towards the organization in achieving its objectives. The study also gives an opportunity to interact with the people working in the organization. An organization study will help in having a better idea about the functions of each department in detail and the duties and responsibilities of each and every personnel in a particular department. It will also provide better picture about the organization structure and the hierarchy of various positions in the organization. The study also gives a better understanding about the history of the company and its different phases of development since its inception. It also helps in identifying and studying the various policies, procedures and programs adopted by the company. The study identifies the industry to which the organization belongs and its importance in the world, country and state. The study also throws light into the future plans of the company. It also helps in identifying and studying the various policies, procedures and programs adopted by the company. The organization study conducted as part of the curriculum so as to make the student familiar with the working of the organization. The project was intended to be an area for experiential and an opportunity for gaining knowledge about the dynamics of the organization. The study aims at providing a practical experience about the various management theories and its application in an organizations functions. During the study it was experienced that the theoretical aspects of management and its practical applications are entirely different.

COMPANY PROFILE

COMPANY PROFILE
The Primi tex Spinning Mills ltd is started during the year 1964 with a capacity of 12000 spindles; the main market of this mill is Mumbai. At present the capacity of mill is 20192. Most of the machines used is about 20-30 year of old. This company registered under Tamilnadu spinning societies Act 1932.

Policy statement of the company


Designing and producing products that meet the market demand. In addition to that it also ensure total customer satisfaction. If these goals are achieved it will become a profitable sustainable company. The company will achieve their objectives through excellence in the area of a) Customer satisfaction. b) Quality. c) Cost reduction

MANAGEMENT
This mill is managed by board of directors. The companys major policies and decision s are taken by board of directors. The board of directors is elected by the share holders. The ultimate owner of company is shareholders. Thus the right to control may be he power defined as the power of share holder r to appoint the director. If the director fails in protecting the interest of the shareholder they may be replaced. The general manger is the chief executive officer. The management setup in the mill is given in the organizational chart. The duty management should be to reduce the excess expenditure. In some cases the company may have to go through complete organization. The company also adopts modernization programs for survival of the mills as competitive units Managing director Chairman General Manger Spinning master Assistant master Supervisor Mr. Sivakumar V. Narayanan Bharathan Chandra shekaran K.M.Jayarajan,Jayadevan,Nijesh,Haresh

ORGANIZATIONAL STRUCTURE

GM

Deputy Spinning Manager

Deputy Manager (Accounts)

Manager (Personnel)

Technical Asst. (Electrical)

Asst Spinning Mnanager

Accounts Staff

Time office Supervisory Staff Quality Control

Personnel Manager

Security Inspector Workers

DEPARTMENTS
The main departments working in this mill is: Production department Personnel/ administrative department Marketing department Purchase department Sales department Store department These are the main departments working in this but there is other departments working which we do give prior importance but without these departments the other departments would be ineffective and they have important role in the spinning mill. This other departments are SQC department Workshop Waste department Security section Electrical department Canteen

PRIMI TEX SPINNING MILLS LTD MARKET


The main market of the product in the mill is at Mumbai, Maharashtra State. The mill also distributes its product to NHDC Cannanore and local market

CAPACITY
The licensed installed as well as commissioned capacity of the mill is 20192 spindles. 47 spinning machines are there in this company. When the company was started there were 72 machines but now it has reduced to 47.

PRODUCT RANGE
Product range of the mill varies according to customers requirements. Presently the mill has been mainly producing 60s cone, 65s cone, 40s cone. Earlier the mill was producing 20s cone also.

PRODUCT PROFILE:
Raw material: Cotton, Polyester, Staple fiber Product : yarn, Cotton, Polyester

Plant Location
The Primi tex spinning Mill is located in chovva. Chovva is a place in kannur district. Chovva mainly consist two areas Thazhe chovaa and Melechovva. This mill is located at melechovva. Cannanore spinning mill is a large scale industry functioning in this area. This mill is approx 7 km from Cannanore town.

Plant layout
The plant layout of this industry is process layout. Here the department are not grouped together. Every department is working separately in different sections. But as they working differently also they are interconnected that is without purchasing department production cannot be done and without production department sales department cannot do anything.

PRODUCTION DEPARTMENT

PRODUCTION DEPARTMENT
Production department management refers to the application of management principles to the production function. In other words production management involves application of planning, organization, directing and controlling to the production process. Production management covers activities such as procuring and installing machinery, purchasing and storing materials and converting to saleable products added to the above are other related areas such as quality management, maintenance management, production planning and control and work simplification. The various activities involved in production planning are designing product, determining the equipment and capacity requirement , designing the layout of the physical facilities, determining the sequences of operations. The activities of production control is to provide optimum utilization of resources, co-ordinate and monitor production activities. Production is the functional area responsible for turning inputs into finished out puts through a series of production processes. The production depart will set standards and targets for each sections of the production process. The quantity and quality of products coming off a production line will be closely monitored by all employees very stage of production. The control of production is one of the important problems of production management. The plant is organized and operated primary object of producing goods. Manufacturing firm acquires raw materials like cotton and perform the production function by transforming them into finished products like textiles

FLOW CHART OF PRODUCTION PROCESS

MIXING

BLOW ROOM

CARDING

DRAWING

SIMPLEX

SPINNING

CONE WINDING

PACKING

Mixing
This is first stage in production process. The raw material cotton is brought from different stations and they are taken in this department of different varieties mainly of 40s and 60s cotton.3000 kilo cotton is brought in one day. In this mill mixing is done by hand

Function Of Mixing
Uniform mix different types of cotton Open cotton Conditioning Firstly, the cotton is brought in the lorry. 1 lorry is two tons of cotton. When this cotton brought the people open the cotton which is brought in pressed form and then the cotton is mixed in this department and conditions it. It is conditioned according to room temperature and atmosphere conditions and these materials are stocked in this department.

Blowroom
From here mixing process takes place Here the raw materials is cotton. Different varieties of cotton are seen in the blow room. Mainly there are two varieties of cotton are seen in the blow room. -40s and60s. the difference is that 60s cotton is of good quality than 40s quality index used formula is: FQI=LSM F (where FQI= fiber quality index, LSM length strength & maturity, F- fitness) LSm should be more and fitness should be less) (here

Fibre Length
Length Fiber length is defined as the average length of the longer on-half of the fibers(upper half mean length). Fiber length is basically an inherited/ genetically character of the seed variety. However weather, nutrient deficiencies, as well as cleaning and or dying at the gin may also affect the fiber length. By effecting yarn strength and evenness, and efficiency of the spinning process, the length of the fiber has a great influence on quality and price. Two machines are mainly used in blow room. They are generally known as scuther. Scutcher means continues group of machinery. The sequence of machine is installed in this department to blend open and clean raw materials. In this department raw material is conditioned that is kept covered. In this department 60s cotton and 40s cotton is kept separate and then it is conditioned. The conditioned is done for one day. Then the cotton is fed into the machine. The machine name is called TRUTZ SCHLER( MADE BY TRUMAC INDIA). Here the cotton passes though air pressure and waste falls down and cotton passes. The main purpose of this department is maximum of waste removal. The 60s waste is called pnrumafil waste and 40s waste is called bondas waste

Functions Of Blowroom: Opening Cleaning Blending/ mixing Waste removal Uniform feed to the caring machine Recycling the waste Micro dust removal

Blow room installation consist of a sequence of different machines to carry out operations.

Technologucal Point Of Blowroom


Every blow room machine can shatter particles, as far as possible a lot of impurities should be eliminated at the start of the process. Opening should be followed immediately by cleaning, if possible the same machine. Cleaning is made more difficult if the impurities of dirty cotton are distributed through a larger quantity of material by mixing with clean cotton. The cleaning efficiency is strongly dependent on thrash percentage. It is also affected by the size of the particle and sickness of cotton. Therefore cleaning efficiency can be different for different cottons with same trash percentage.

Carding
In this department impurities or waste is removed and fiber must be straightened. This straightening is done by arranging the fibers in parallel fashion which is called carding.

Functions Of Carding
Waste Removal Paralisation Make It Into Silver Form Carding separate fiber from each other, straightens fiber, condenses them into a single continuous stand, and removes impurities. Carding is the process of straightening and paralleling of fibers. In this department they get 5% thrash. Mainly the object of this department is to clean the raw materials and the short fibers are removed in these machines. It is also called heart of the spinning process

There are two type of machine. Old machine and new form of machine. Old forms of machine make cotton into lap for that is sheet form New form of machine s called chute line or chute feeding system. Here the cotton is made in to rope form. The new of machine is computerized system The sheet form of cotton is called at it will be of16 kilo weight and 40 meter system. The rope form of cotton is called silver. In this waste will not be there uniformity will increase.

PRODUCT RANGE 40s 1. production required in the carding system 2. number of allotted for each count 3. hank of silver delivered 4. licker the speed, cylinder speed,doffer speed RPM 5. efficiency 6. production in kg/ 8 hours/ cash 7. total production/ shift in kgs 8. % of salable waste 9. % of white waste 1098 95 293 586 5.8 .25 47868 95 293 586 5.2 2 1365 2 .14 62s/65s 1563 2 .14

Drawing
From carding the raw materials are brought and stored it in drawing department in different cans. The silver is stored in the can. Mainly 8 cans will be kept in this department. The silver is passed through a machine. The machine has 2 roller. Rubber cotton roller Steel cotton roller

Here pressure is put from 2 rollers and the output received is called silver ( the output of carding and drawing is called silver). The object of drawing is doubling and paralisation of fibres. Paralisation makes silver parallel and it helps in proper drafting while doubling improves the quality. (doubling is not done now in this mill

A FUNCTION OF DRAWING IS: Drafting Thorough blending Make uniformity As a result of drawing the silver is condensed into a thinner strand and becomes more uniform. In drawing silver is made into thinner strand and winds it on a bobbin Product range 40s 1. production/ shift of 8 hours in kgs required number allotted 2. number of silver fed in breaker / finisher 3. hank delivered in breaker/ finisher 4. delivery speed in meters in breaker 5. efficiency finisher 6. draft in breaker 7. average production/ shift in kgs( finisher) .72 8 .16 225 85 7.5/7.5 668 .76 8 .16 22400 85-90 7.5/7.5 643 1358 62/65s 1555

Simplex
The next department is simplex. From this department the size of the silver will get reduced. In this department 60s machine and 40s machine is used. In this department silver passes through the codes and forms into thin threads known as roving products. The output of this machine is called roving or bobbin

A Functions Of Simplex Is
drafting twisting make it roving Twisting means many yarns are piled together it increase the dia meter and tensile strength. In principle strands are twisted together in the opposite direction to the spinning twist. The machine prepares the drawing silver for spinning the yarn to suitable count. Silver from the drawing machine is drafted in this machines and small twist is given to blind the material together Product range 40s 1. production/ shift of 8 hours in kgs required number allotted 2. spindles speed 3. % of whit waste in simplex 4. hank of roving delivered 5. average production in HKS/ 8 hrs 6. total production in kgs/ 8 hrs 7. average weight of full dobbin 8. end breakage/ 100 spindle/ hrs 861 1.0 1.8 1428 528 900 gm 920 1.0 2.25 3496 662 900gm 1351 62s/ 65s 1547

Spinning
The last step is spinning. This department is called ring frame. In this department, the roving product is drafted as per the count. The drafted material is twisted to form the yarn. In spinning frame reduces roving t required size of single yarn. Spinning is the process of making yarn from fibers.

A Fnction Of Spinning Is: Drafting Twisting Make it in yarn In spinning department 3 models of machine are used such as Textool 5hs Testool Dj50 Lmw Company-Gs/1 In one machine 400 spindles are used. These machines will cost Rupees 7 lakh. The running power of machine is 15000RP. In this, TEXTOOL DJ50 uses 400 spindles; LMW COMPANY-GS/1 uses 864 spindles so the cost of this machine is more than33 lakh. When this machine work for 6 hours we get output of 23 to 24 kilo thread.

Drafting
Drafting is thinning down the material and this is getting affected by a set of rollers running a graduate speed in drawing, simplex and spinning machinery.

Cone winding
In the winding process, the yarn span on the sing frame is wound on paper cones. With the help of slab catchers provided on the winding machines all the spinning are removed. Therefore are 3 cones winding with 120 drums each

THE FUNCTION OS CONE WINDING: remove thick and thin place make it in a cone form

Cone packing:For packing & easy transportation materials to market the the final yarn is wound on paper cones in cone form in the cone forms from the unwinding becomes easier. At present the weight of the individual cone is maintained at 1.250 kg . in packing section the cone are packed in polythene and woven. Sacks 40 cones are packed in a single bag making it a 50 kg cone bag 1 cone weight = 1.25 kg 40 cone 1 bag = 1 bag = 50 kilo

SALES DEPARTMENT

SALES DEPARTMENT
Selling is important for increasing the profit. Selling refers to the functions and activities undertaken to secure the sale or destruction of product manufacture by the firm. It involves efforts to sell what has been produced. Selling is basically production oriented. Main output produced by the mill is cotton yarn. Mainly two types of cotton yarn produced in this mill such as hank yarn and cone yarn

Varieties of hank yarn: 20s, 40s, 60s, 2/17s, 2/40s, 2/20s Cone yarn:It is producing for supplying to power looms 80% of the yarn produced as corn. All most all cone yarn are out side the state by way of tenders and by way of depot in Bombay mill depot working in Mumbai in 2 places bhiwandi % malagaon. These 2 depots sold all yarns transferred from mill to Mumbai. The mill providing 1.5% commissions for running the depot.

Transportation:

The chief function of physical distribution is to take goods from the places where they are consumed. Transportation has always led to increases in scale of production and specialization of an industry. Quick means of transport have made possible their transportation in transits. The mill used to transfer finished product from mill premises to parties by way of road. The company has vehicle. Mill used to select transport companies by way of invite quotation from transport companies who placed lowest quotation which confirmed by the mill.

FINANCE DEPARTEMENT

FINANCE DEPARTMENT
Finance refers to money, cash or fund available to carry out operations. Financing is an ancillary but important function of marketing. It facilitates working of process in the firm. The provision of fund is essential for meeting various requirement of firm. A firm requires that fund at different stages like to start a company, to operate a company, to expand a company. The importance of finance is needs not over emphasized. Without proper administration of finance, no business can utilize its full potential for the growth and expansion. Money is the universal lubricant which keeps the enterprise dynamic, develops products, keeps men and machines at work, and encourages management to make progress and create values. The chief financial official that is the finance manager is the controller of finance. He is manly for performing for the financial functions. In this enterprise the entire control of finance depends upon this department. The various functions undertaken by this department are:1. Management of finance: Finance has never been problem for entrepreneurs in this cluster. Some times excessive credit given to customers creates temporary shortage in working capital. The

entire enterprise has financial assistance either from commercial banks and financial institutions. How ever stringent type competition, compelling to the manufacturing to supply at less remunerative price, sometimes may create shortage in working capital. The enterprise is well organized in financial planning. Their financial controls and accounting systems are up-to-date and hence they are able to provide right information, balance sheet and profit & loss account to the satisfaction of term lending institutions and banks for getting working capital and term loans. They have accountant to look after their accounts.

2. Key financial activities:


o Financial analysis, planning and control o Assessing the financial performance and the working condition of the firm.

o Forecasting and planning financial structure of the firm. Appropriate system of control to ensure that actions of manager are ; Concurrent with the goals of the firm. Management of firms asset structure

Determining the capital budget Establishing credit policies Managing the liquid resources Controlling the level of inventories Management of firms financial resources Establishing the dept equity ratio or financial leverage. Determining the debt and dividend policy Timely payment shares Negotiating and developing the relationship with various suppliers

Maintaining book of accounts


Register of maintaining shares. Cash book-Cash receipt, Cash payments. Purchase day book Sales day book Journal proper. Day book.

PURCHASING DEPARTEMENT

PURCHASING DEPARTMENT
The purchasing department will be responsible for providing the materials, components and equipments required to keep the production process running smoothly. A vital aspect of this role is ensuring stocks arrive on time and to right quantity. In Primi Tex Spinning Mill the purchase department is set up under the production department.

Cotton:The mill main raw material is cotton. The mill purchase raw materials from outside state like Karnataka, Andhra Pradesh, Maharashtra, Gujarat, Punjab etc. Purchase is made on the basis of Tenders. Mill gives purchase order to the parties on the basis of lowest quotation offered by the parties. The mill purchased different varieties of cottons of different count such as:-

Counts Varieties

40s MECH LRA BUNNY MCU-5 BHRMA RCH H-6

60s MCU-5 DCH-32 H-4 BUNNY

Packing materials:Another purchase be made for running the mill. Mill wants to pack the finished products so mill purchase packing materials from different states. Packing materials are: Labels Bags(Polythene bags) Jute yarn.

Store materials:For day to running of the mill numerous store materials are required by the mill that is part of machines. It is also purchased from within the states and outside state. All purchases are made from different parties.

STORES DEPARTEMENT

STORES DEPARTEMENT
There is need to provide for storage of raw material in a plant until they are converted into finished products. The factory buys raw material economically when they are available and should be stored properly. The stores department will be responsible for the stocking all the necessary tools, spares, raw materials and equipment required to service the manufacturing process. The store department is connected with physical handling and well-being of the stock. The stores department is meant for stocking purchased material, but partly finished goods, spares and consumables are also kept in stores. If the goods are not sold off immediately the manufacturer has to make adequate arrangements for storage of his output. An efficient storage yields the following benefits: Ease of handling Minimum of wastage Efficient space management Ready accessibility of major materials permitting efficient services to the users.

CONCLUSION

CONCLUSION
The Primi Tex Spinning Mills Ltd have made considerable achievements in the area of Textile industries. The company has operational experience of more than 40 years. Dedicated work and vision of the management has enabled the company to reach its position today. Companys brand image and loyalty is worth considering. Through their efforts and quality, company has able to establish a good reputation. The market and goodwill it enjoys appreciable indeed.