INDUSTRIAL TRAINING REPORT SUBMITTED TO MAHATMA GANDHI UNIVERSITY KOTTAYAM In partial fulfillment of the requirements for the award

of the degree of MASTER OF TECHNOLOGY IN INDUSTRIAL ENGINEERING AND MANAGEMENT

Submitted By HARIKRISHNA PAI (Reg. No: 300256)

DEPARTMENT OF MECHANICAL ENGINEERING RAJIV GANDHI INSTITUTE OF TECHNOLOGY (GOVERNMENT ENGINEERING COLLEGE) KOTTAYAM 2010-2012

DEPARTMENT OF MECHANICAL ENGINEERING RAJIV GANDHI INSTITUTE OF TECHNOLOGY GOVERNMENT ENGINEERING COLLEGE, KOTTAYAM

CERTIFICATE This is to certify that this Industrial Training report is a bonafide record of the work done by Mr. HARIKRISHNA PAI in partial fulfillment of the requirements for the award of the Degree of Master of Technology in Industrial Engineering and Management under Mahatma Gandhi University, Kottayam

Dr.R.Sasikumar Professor (Guide) Dept. of Mechanical Engg. Engg. RIT Kottayam

Shri.Pradeepkumar.P PG Coordinator Dept. of Mechanical RIT, Kottayam

Dr.M.S.Jayamohan Professor & Head Dept. of Mechanical Engg. RIT, Kottayam

ACKNOWLEDGEMENT
I have received tremendous support and guidance from the staff members of my department and Precot meridian A unit for the successful completion of the industrial training. I would like to express my thanks to Shri.John, Deputy General Manager, Precot A unit & Shri.V.Guruvayoorappan, HR manager, Precot A unit for permitting me to do training in this organization. I would like to express my deep gratitude to Shri.Anish, HR trainer, Precot A unit for guiding me all through the work. I express my sincere gratitude to Shri.V.Krishnaprasad, Sr. officer(S & D), Precot A unit & Shri.Suresh, Plant house in-charge, Precot A unit for their kind support in the work. I would also like to express my heartfelt gratitude to Dr.M.S.Jayamohan, the head of the department of Mechanical Engineering for his tremendous guidance and support.I specially thank Dr.R.Sasikumar, who took immense effort in guiding this work .I would also like to thank our PG Coordinator Shri. Pradeepkumar P for the motivation and support he has given me in connection with the training. I would like to express my sincere and profound gratitude to Dr. S Jayakumar, Prof.Biju Augustine.P, Prof. Ciby Thomas, Associate Professors, Department of Mechanical Engineering for their valuable guidance and support. I would also like to thank all the staff members of the Department of Mechanical Engineering for providing me with all facilities and support. I would also like to thank all the managers and workers of Precot A unit for sharing their knowledge for me. I also thank my parents and all my dear friends whose suggestions and timely help put me on the track in the timely completion of the work. Last but not the least I would like to thank God the Almighty for all the blessings he is showering on us. KOTTAYAM 09/01/2012 HARIKRISHNA PAI

CONTENTS Chapter 1: Introduction 1.1 Introduction 1.2 Methodology 1.3 Objectives 1.4 Textile Industry 1.5 Indian Textile Industry 1.5.1 1.5.2 1.5.3 1.5.4 Textile sectors in India Market size Textile Exports & Imports Opportunities in the Indian Textile Industry 1 1 1 2 2 2 4 5 6 8 9 9 9 10 11 Product Range 11 15 15 15 16 17 18 18 19 19 19 19

Chapter 2: Company Profile 2.1 About Precot 2.2 Growth of the company over the years 2.3 Precot: units 2.4 Products 2.4.1 Chapter 3: Precot A Unit 3.1 Precot A Unit at a glance 3.2 Yarn: count and End Uses 3.3 Product: share in Production 3.4 Market 3.5 Precot A Unit: Milestones 3.6 Capacity Expansion over the years 3.7 Departments 3.7.1 Production department 3.7.1.1 Preparatory Department 3.7.1.2 Spinning Department

3.7.1.3 Finishing Department 20 3.7.2 3.7.3 3.7.4 3.7.5 3.7.6 Quality Assurance department Electrical Department Maintenance department Administrative department Human Resource department 20 20 20 21 21 22 22 22 23 23 24

3.8 Organisation Structure 3.8.1 3.8.2 Manpower Working Hours

3.9 Cotton Yarn Manufacturing Process 3.9.1 3.9.2 3.9.3 Preparatory Department Spinning Department Finishing Department 24 3.10 Management Initiatives 3.10.1 Machinery 3.10.2 Quality control 3.10.3 Enterprise Resource Planning 3.10.4 5S 3.10.5 Employee Welfare & Social Commitment 3.11 Awards Won by Precot in recent Years 3.12 Production Planning and Control Chapter 4: Performance Analysis 4.1 Production & Sales Performance 4.2 Sales/profit over the years 4.3 Capacity Utilization 4.4 Unit efficiency Chapter 5: SWOT Analysis

24 24 25 26 27 28 29 30 31 31 30 31 35 36

5.1 SWOT Analysis 5.2 SWOT Analysis at Precot A Unit 5.3 Strengths: A closer view 5.4 Weakness: A closer view 5.5 Opportunities: A closer view 5.6 Threats: A closer view 5.7 Problem Identification: Cause & Effect Relationship 5.8 Prospects of productivity improvement & Capacity Expansion: The Indian Textile Scenario Chapter 6: Findings, Suggestions & Recommendations 6.1 Findings 6.2 Suggestions & Recommendations 6.3 Limitations of the Study 6.4 Conclusion References Annexure

36 38 40 41 42 42 43

45 46 46 47 47 48 49 50