INDEX OF REPORT

Sr. No. 1 Industry Profile

Subject

Page No. 1

Company Profile

Finance Department

14

HR Department

40

Production Department

71

Marketing Department

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World fiber consumption grew by 3.8% in 2006. of this cotton grew by 2.5% and polyester by 4.4%. Polyester filament yarn, the fastest growing major fiber category, and the industry in which your company operates, grew by 6.5% worldwide. China and India are the worlds largest PFY producers. Moreover, PFY growth is completely dominated by these 2 countries. This domination is expected to continue. The world PFY growth, excluding China and India, is strongly negative. Indias PFY industry is still a little over a tenth of the size of China but our growth is expected to be faster. Indias economy has been growing at an unprecedented rate of 8.6% per annum over the last 4 years. Manufacturing has been a great contributor; growing at 9.5% p.a. the accelerated growth of the company has substantially impacted the PFY industry growth as well, which has outperformed the real GDP growth. After a lull for a few years the industry grew dramatically last year eliminating the oversupply that industry observers had predicted would last for a few years more. While capacity grew by 38% to over 2 million TPA, production grew even faster. The growth was due to both export demand as well as domestic consumption. The Indian cotton crop is owing to the rapid increase in yields made possible by increased use of BT cotton and improved water management. However, this is not expected to impact the Indian polyester industry since the global shortage of cotton should imply high cotton prices. In the last budget, import duties on PFY and its raw materials PTA and MFG were reduced form 10% to 7.5%. During the year under review, excise duty on MFG was reduced from 16% to 12% which continues to be much higher than the 8% on PFY and remain an unfortunate anomaly. The Company operates across the entire polyester chain from polyester chips to finished fabrics. The party insulates it form temporary oversupply in any one component of the chain. It also gives the Company valuable information about final consumer and raw material trends. It also enables it to sense and respond to market movements quickly. Mostly, however, it allows for great synergies in product development that give the company an edge in product innovation and quality. The Companys leadership in product differentiation,

product quality and thus price realization gives it the opportunity and justification to grow rapidly in the fast growing PFY industry. The PFY market is the largest synthetic yarn market in India and accounts for over 50% of the total demand for synthetic yarn. Surat and its outskirts provide the largest market for PFY being the heart of the polyester filament weaving and processing industry. The companys manufacturing units have a locational advantage being situated in the heart of the polyester textile industry. Its location gives it proximity to both raw material suppliers as well as end users. The Surat area is also the most innovative textile center which gives the company a natural outlet for its specialty fabrics and yarns. Since the companys primary market is Surat, the ongoing and proposed expansion plans involve considerable production of final down stream/drawn yarn in particular fully drawn yarn and texturised yarn. The company enjoys a strong brand for its fabrics and yarns that has been built over the years. Its fabric distribution network is strong and spread across the country. Its fabric engineering and design capability is second to none in the country.

TEXTILE INDUSTRY IN SURAT

In India the main manufacturing of the textiles is done in the SURAT city. The SURAT textile industry has the largest concentration of looms in the world leaving manmade fabrics. It has a total coverage of approximately 1.75 lakhs which is even larger than that of Ahmedabad and Mumbai.

HISTORY OF DEVELOPMENT IN SURAT

It is unbelievable that Surat is the largest center in the world for the production of synthetic fabrics like nylon and polyester. Daily production is about 42lakhs meters valued at Rs 4 crores per day. There are about 160 process houses, which processes nearly 25 lakhs meters per day. The industries in SURAT employees more than 1 lakh workers The beginning of the industry in SURAT is hardly 35 years old. Today, the number of authorized looms in SURAT is approximately 4 lakhs, though the total number of looms are anywhere between 1.5 and 1.8 lakhs. It is known from the reports that daily new machines are imported from china and Korea. There is new trend came which is known is sequence embroidery. These machines costs about 7 to 8 lakhs per machine but it designs many sarees at a time with the help of the computer. These machines are imported from China and Korea generally. In the 1950s, there were only about 7000 power looms in SURAT. The 10 families who have played a leading role for the growth of the industries are Bachkaniwalas, Hathiwala, Vakharia, Dhamanwala, Mahatma, Dr. Amichand Shah, Chevli and Lekhadia. Now days the Textiles business is very big in the SURAT, So, now the SURAT is known as the Textile City.

Garden

SilkMillsLtd. Is one of the Indias largest vertically integrated textile

companies with particular strengths in Polyester filaments based Textiles & yarns.

Garden Vareli group of companies, one of the leading industrial groups in India, plays a leading role in the field of fashion fabrics. With annual sales exceeding U.S. $ 90 million, they sell their products under a single banner of quality Garden. GARDEN SILK MILLS LTD. is public limited company incorporate on July 23, 1979. It was authorized share capital of Rs. 60 crores, Equity shares of Rs. 10 each, out of which around Rs. 3, 82, 90,560 have been issued, subscribed and fully paid up. The shareholders here have seen much appreciation and received regular dividends which impose that the company is getting on prosperous year and is profit making venture. This is attribution to the three generation of the directors who have strived hard for the growth and progress of the company. The company has also seen much of highs and lows of the market and has successfully come out of all those, providing it to be a leader of textiles business of all times. The company has three production plants : One Vareli complex, at Village Vareli, Near Kadodara Junction,taluka palsana, National Highway .No.8, The Second at Village Jolwa, Near Bardoli, dist. surat and the Registered office at Garden Mills Complex, Sahara Gate, Surat. Today the company has total 293 its own retail and authorized outlets all over india. The company is having a very setup, with plants to manufacture dress material and sarees, right from the initial stage, viz, chemicals to finished fabrics. This has been possible because of the companys large capital base, attributable mainly to the large amount of sh are capital raised; reserve of various kinds being cautiously preserved and the loans form bank and financial institutions. The company had also raised capital through debenture in the past, majority of that have been repaid now. Since our inception we have been delivering excellent financial result year after year. This statement year the financial statement was placed before the board of directors and taken on record at their meeting.

Garden Silk Mills Ltd. is one of the leading & oldest manufactures of synthetic in India. Garden Silk Mills Ltd. has been exporting their products to European markets since late 1970s. The company has made vertical & horizontal integration from its establishment. The company has achieved a very good brand name in Indian & International market of sarees & dress materials.The company has achieved sales during financial year 2005-2006 of Rs.95,485.95 lacs & for the year 2006-2007 Rs.45,750.23 lacs.
The company has grown in all term during fast few year, in the economics prosperity and in the form of larger asset creation, making Garden Vareli to be leader of all times among textiles companies of the nation. It achieved ISO 9002 on February, 2000, which was its greatest achievement, and Garden Silk Mills become the first company ever achieve such creation in Surat.

This has brought fame to the city and to the nation all through the international sales and export income has been considerable. The company is expending even now and planned to increase its capacity in a phased manner until 2002.
The company is largest manufactured of POY and PFY in India. The company is the competitors of RELIANCE. The companys strategy is not to be top in the POY, but they are interested in to make the quality product which satisfy the customer needs at the most.

ACHIEVEMENTS OF COMPANY

The company was first to setup a polyester filaments yarn project in south Gujarat. The project is capable of producing multi-filament & micro-filament yarn having a capacity of 5,000 tones per annum in collaboration with non-val leasina ag of switzerland. This project has a special significance for the company, as polyester filament yarn is the basic raw material for the product manufactured by the company. The company was also first in producing of two-for-one twister in india. The company's production facilities boast of one of india's most sophisticated textile plants at vareli, surat (Western India). Its weaving plant comprising nissan and tsudakoma waterjet looms - the highest number of waterjet looms under one roof in india - and rapier looms, automatic shuttle change looms etc, high-tech yarn preparatory machines viz, zirotwist-sizing, draw-warping, texturising and twisting machines, have a capacity of over 42 lac meters/month of greige fabric. The plant has an iso 9002 certification by bvqi. The company

also markets high quality dyed and printed fabrics which it gets manufactured from associated firms.

HISTORY OF ORGANIZATION

The origins of the business go back to 1920 when Mr.Amichand shah installed the first hattersley looms in surat. The company belongs to Garden Vareli Group, which is one of the preceding manufactures of synthetic textiles in the country. Since 1920 the company expanded not only by increasing the production capacity and workforce of the business but also by pioneering new material and processes. To the early beginning of the art silk industry in Surat. Garden Silk Weaving Factory, as it was then named, manufacturing viscose becomes leader in jacquard fabric for years to come. The managing director of Garden Silk Mills Limited, Mr. Praful Shah is the youngest son of the founder, Dr Amichand Shah. He gained the degree in engineering from the university of Stanford in the USA in 1965 after which he joined the business prior in that date. He even extended the activities of the company to include processing cloth and even processing cloth. As a result of this the company was able to supply finished textiles for the first time. This move in the early 1970s conceded with the opening of the first retail shop in Surat. The extension of the policy of vertical immigration into the retailing sector had advantages of uniform pricing, close market monitoring, communications between manufacturer and consumer and above all the exerting downward pressure on the final selling price. The dedicated retail network now extends to some 293 authorized outlets. In 1975, the company recruited Fine Arts Graduates from leading institutions and an Art studio was set up. The company started introducing its own designs and supplied these designs in the market. Prior to this, the designs produced had been a function of customer demand and from this point onwards, the emphasis changed the design impetus coming from manufacturers.

In the late 1970s, the company started exporting its products to European Market, Given the size of the domestics market, the proportion of the product that are exported remain low at approximately 2% The Company is in the process of further developing market in Africa, Central and Eastern Asia. In the 1980s, the company developed a new site-Vareli, some 12kms away from Surat. This has become the manufacturing plant and investment of more than 2 billion has been made. Most of this expenditure has been targeted at the expansion and modernization of plant and equipment, particularly in the weaving and yarn preparatory sections. As a result, the company today has one of the most modern and sophisticated textile plants in India. The company has further its policy of vertical Integration by setting up a new plant, also near Surat, from which it will manufacture polyester filament yarn, one of its principle raw materials from polyester chips. Today, the company is one of the largest manufacturers in India of high fashioned, premium quality, dyed and printed textiles fabrics, both polyester and viscose comprising a range of chiffon and georgettes, crepes and faithful ladies, fashion as well as Indian sarees, The company also manufacturers an exclusive range of pure silk and cotton fabrics. The fabrics are marketed under the famous names Garden and Vareli.

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LOCATION OF OFFICES, BRANCHES & FACTORIES

REGISTERED OFFICE
Sahara Gate, Surat 395 010. Tel: (0261)2311197-98, 2311615 Fax :( 0261)2311029/502 Email: sharedepartment@gardenvareli.com

FACTORY/PLANT
Vareli complex, Village Vareli, Taluka. Palsana, Dist. Surat 394 327 Tel: (02622) 271241 47

FACTORY/PLANT
Village Jolva, Taluka. Palsana, Dist. Surat 394 305 Tel: (02622) 271287-89

CORPORATE OFFICE
Manek Mahal, 90, Veer Nariman Road, Church gate, Mumbai-400 020 Tel: (022) 2287 3117-19 Fax: (022) 2204 8112

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Details of Promoters and Owners

NAME Praful A Shah Shilpa P Shah Suhail P Shah Arunchandra N Jariwala Yatish Parekh Smita J Shah Anjan Mukherjee Alok P Shah Sanjay S Shah Rajen P Shah J P Shah Sunil S Sheth Madanial U Lankapati

DESIGANATION Chairman and Managing director Executive Director Executive Director Director Director Director Nominee Director Joint Managing Director Executive Director Director Director Director Director

Future plans of organization

GSM commenced commercial production of its new Continuous Polymerization (CP) project increasing the production capacity from216,000 TPA to 416,000 TPA from January 2009 on schedule and within budget. In March- June 09 the Company commissioned the latest technology POY and FDY equipments adding further spinning capacity of about 55,000 TPA.GSM has further undertaken an expansion project involving enhancement of Polyester textile grade Chips Capacity by 130,000 TPA which is expected to be commissioned by February of 2010. This will further enhance our capability to serve our

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clients demand of non-commodity chips, of which Garden is a leading supplier. Attache to this plant, as well as the older CP plants, machinery to directly spin a diverse range of yarns is in the preliminary project stage. This will downstream about 138,000 TPA of polymer into directly spun POY & FDY yarns. In addition, 11,000 TPA of semi-dull chips will feed specialized extruder-spun yarns in the same premises. The estimated completion date of these downstream projects is Q3 of 2010-11. In the year under review the original CP plant has been modified to optionally manufacture high-value polymeric chips for film-grade applications and textile applications requiring optical brightener additives. In order to maintain uninterrupted power supply to support these projects, your Company is setting up an 18MW power plant. The total cost for the upcoming projects is estimated to be around Rs400 cores.

CORPORATE GOALS AND OBJECTIVES

Companys has its own culture and identity in business world. It is the effort of the company to maintain this identity and be leading in global market. Company has fixed its goal and laid down some certain missions to achieve them.

CORPORATE GOALS

Maximum return to share holders. To improve companys position in business. To keep a slim and trim but fully satisfied management team to operate faster and to
achieve higher levels of business and growth effectively. To ensure quality at all stages.

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Oganisation Structure Of The Company

Top management (All partner)

Chairman

Managing director

General Manager

Production

Marketing

Finance

Human resource

Manager

Manager

Manager

Manager

Asst. manager

Sales executives

C.A.

Asst. manager

Workers

Asst. manager Staff

Comp operators .

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ORGANIZATION STRUCTURE OF FINANCE DEPARTMENT

Director

General Manager

Excutive Manger

Company Secratary

Legal Matters

Tax Consultant

Jr. Executive

Staff

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CIRCULATING CAPITAL STRUCTURE OF GARDEN SILK MILLS

CASH

RAW MATERIAL &COMPONENTS

TRADE CREDITOR

CURRENT ASSETS CYCLE WORK- INPROGRESS TRADE DEBTORS SALES FINISHING PRODUCTS

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ORGANIZATION STRUCTURE OF HR DEPARTMENT

Director

M.D.

G.M

Assist. Manager

Staff

Vision & Mission of the Garden Silk Mills

Vision of the Garden Silk Mills: Vision is to manufacture product as par international standards and compete international textile industries.

Mission of the Garden Silk Mills: Customer satisfaction is there ultimate mission.

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ACTIVITY OF HUMAN RESOURCE DEPARTMENT

Organization planning Human Resource Planning Job Analysis Job Description Job Specification

Acquisition of human resource Managing performance motivational activities training and Development Compensation and Benefits Health and safety provision organization Development encouraging participation in management Grievance procedure etc.

HUMAN RESOURCE PLANNING

HRP is the process of forecasting an organizations future demand for, and supply of, the right type of people in the right number. HRP facilitates the realization of the companys objectives by providing the right number of personnels.

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HRP Process

HRP - Process

Internal

External

Oraganizational Decisions

Political,Legal,Social Changes

Workforce Factors

Competition

Forcasting Techniques

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Forecasting refers to the estimates of the future demand of the employee. This can be done by some analysis. And to do analysis it considers some factors. There are mainly two factors which are as follows:1. External factors. 2. Internal factors.

1. EXTERNAL FACTORS. A). POLITICAL, LEGAL, SOCIAL AND THE TECHNICAL CHANGES. The demand for certain categories of employees and skills is also influenced by changes in political, legal and social structure of an economy. In the Garden Company, it has appointed the technicians and engineers during the last couple of years by taking into consideration the latest technology in construction, software etc. the company considers technology as a doubled-edged weapon. So, as a when the technology changes, the company will also recruit new technicians & engineers to cope with the technology. B). COMPETITION. Garden company is operating in a field where a large number of players are bent while cutting each others throat. In order to stay in a competitive market, the company has to LEAN by reducing their workforce. The company is planning better workforce as competition has so much increased in the market. On the other hand, the company is doing well and also progressing smoothly so it will always look for people with critical skills.

2. INTERNAL FACTORS. A). ORGANIZATIONAL DECISIONS. In planning H.R., the company undertakes the strategic plan; it takes into consideration the sales and the production forecasts. The company is expecting higher demand of textured yarn and for this, the company has planned long-term plan. Moreover, the company is in search of people possessing requisite skills in next couple of years.

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B). WORKFORCE FACTORS. The demand for new job occurs because of retrenchments transactions, resignations, deaths and leaves or absence. The Garden behaves that due to past experience the rate of occurrence of all these actions by employees are partly predictable. C). FORECASTING TECHNIQUES. The manpower forecasting techniques employed by the Garden Company are described below a. Experts forecasting: In the Garden Company, managers estimate future human resource requirements. Sometimes, the company also appoints the experts to forecast human resources along with the managers experience and judgments which gives the good effect. b. Trend Analysis : The Garden company is deciding or forecasting its H.R. needs through projecting past trends. Past rates of change can be projected into the future or employment growth can be estimated by its relationship with a particular index.

LABOUR WELFARE ACTIVITIES

CANTEEN FACILITY It is providing employees the facility of break fast, lunch and dinner at the reasonable prices. REST ROOM The rest room facility is given to the workers to take rest during the lunch time and even during the free time. UNIFORMS The workers are given the uniform which they are supposed to wear during the office hours.

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 SHOES AND RAINCOATS All the employees and the workers of the company are given the shoes and raincoats during the monsoon. FIRST AID FACILITY It is given for quick remedy of employees, when any accident occurs during the working hours of the organization. SCHOLARSHIP Company provides the scholarship to the workers and the employees to those who study for the company as a trainee. TRANSPORTATION (BUS) FACILITY The company also provides the bus facility for the workers from Vareli to bela mills and even from Jolwa to silk mills for to and fro of the workers.

OTHER FACILITIES

Transport facilities are available for SURAT addressee to all staff and workers and some contractors Labour Gratuity is given for 15 days for each year worked if completed 05 years Med claim is provided to the staff with family approx between 25k to 85k and single staff is provided med claim up to 15k. Probation is provided for 6 months to experience employees and 1 year to the others.

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Confirmation letter is issued upon the assessment on completion of probation period. The retirement age of the employees is 58 years. There are total 4 shifts and timing of which are as follows:Shift A 07:00 am to 03:00 pm Shift B 03:00 pm to 11:00 pm Shift C 11:00 pm to 07:00 am General Shift 09:30 am to 06:30 pm The timing for Saturday is 09:30 am to 03:00 pm.

The car policy is provided to the managers and other senior officers of the company on selective basis, the company provided 52% of the total policy and 48% is of self.

The increment is provided to the staff in April and to the workers in January. Housing to seniors (Top Management).

LABOUR RELATION ACTIVITIES

Labour relations are concerned with the relationship between management and workers. In Garden Silk Mills Ltd., the Labour relations have been maintained very nicely. It is important for the company to maintain good relations with the Labour otherwise the company cannot come on the position where it is now.

Mr. Naised Desai is the leader of the Labour union of GARDEN SILK MILLS LTD.

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TRADE UNION

Textile industries have two trade unions 1. SURAT silk mills Labour unions 2. Bombay industrial relations act

Generally the employee of the company is not interested in any of the above mentioned trade unions but if any disputes arises and the matter goes to the court than the employee takes the help of the SURAT silk mills Labour unions.

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ORGANIZATION STRUCTURE OF PRODUCTION DEPARTMENT

(HOD)SPG

Sr. manager/dy. manager

production

packing

Asst. manager/ engineer

sr. officer

shift enginer sr. technician/ technical

sr. clerk

worker

worker

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ACTIVITIES IN PRODUCTION DEPARTMENT

To take some knowledge about the production activities done in the GARDEN SILK MILLS, We have visited the production plan at the JOLWA Village. At that we ask them that which kind of activities they carry out. So, they give us the all the detail of their activity.

In JOLWA plant they produce POY (Partially Oriented Yarn). As we know that for the production of the goods the Production Department has to depend on the Marketing Department. They produce only those quantities which are demanded by the Marketing people.

So, some activities done in the Production Department are as follows:--

1. Production manager gathered the information about what to produce and in what quantity. This information must be collected from the Marketing Department. Marketing Department collects information by analysis the market and gives data to Production Department. 2. After receiving information about in what quantity produce, the production manager now does the arrangement of the raw-material. In Garden the R.M is the POY chips which is made from the D.M.T. and E.G. 3. After doing the arrangement of the R.M. the manager starts the production of POY. 4. When the production getting finished the manager check the quality of the all the POY. 5. After checking the goods they packed it in safe boxes. Then the boxes are kept in warehouses. Then as per the dispatch order given by the Marketing Department the Dispatch Manager dispatch the order and send it by trucks.

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ACTIVITIES IN PRODUCTION DEPARTMENT

Marketing Department give forecasted demand to Production Department

Production Manager Decides Production

Production Manager do R.M. Planning

Production Starts

Check Quality of Goods

Packing

Store in Warehouse

Dispatch Goods

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RAW MATERIAL PURCHASE POLICY

Purchase procedure is a very important part in the big company. For production they need R.M. and to purchase the R.M and other item there is a special purchase procedure that all the company follows. In GARDEN there is also a separate purchase department who always take care about the purchase decision in the company. In this company some purchase activity done by purchase department are as follows. Purchase of R.M Purchase of chemicals like spin-finished oil, Lubricants etc Purchase of new imported material. Purchase of capital goods. Purchase of new machinery. The purchase procedure starts when the need of purchase arises.

STEPS IN PURCHASE PROCESS:-

1. The production manager informs to the purchase manager about the need of the Raw Material, some machinery and equipment etc. 2. The purchase manager receives the data and checks whether the demand wrong. 3. After checking the quality and quantity required by production manager, the purchase manager will do inquiry about the potential suppliers. 4. After finding the supplier the purchase manager will send him an inquiry letter and ask for quotation. is right or

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5. In response to the letter the supplier will also give letter related to the price of the goods and other condition. 6. After receiving the letter the manager will compare the quotation of the entire supplier. They will compare the quotation in respect to the unit price of goods, credit policy, and other terms & condition of the supplier. 7. After comparison they finalize the best supplier and then the manager personally checks product quality and if he is satisfies then he places order. 8. After giving order, supplier has to supply it within the given time-period.

So, above are some steps which are generally followed by the purchase manager of the company to purchase Raw Materials, other equipments etc.

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MATERIAL HANDLING EQUIPMENTS

It may be defined as the equipment which controls internal movement of material, from receipt, through storage and production and up to the shipment of finished product.

Material handling equipments are very useful in the big company. This equipment is widely used in company. In GARDEN they use those types of equipments, which are helpful to them in the safe movement of their material.

Material Handling Equipments of Garden Silk Mills:- Pipelines. Trolleys. Fork Lifts. Pallets. Hydraulic Machines. Plastic Bags. Boxes. PIPELINES

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Pipelines are the very important part in the manufacturing company. It is very useful for the flow of the water, gas, air, chemical, and raw-material.

In GARDEN they also use the pipelines for such kind of use. They mainly use pipelines for the flow of R.M. in the production process. They also use pipelines for the flow of air and liquid material.

TROLLEYS

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Trolleys are mainly use for the transfer of goods from one place to another place. We also use trolley at our home. In this way it is also used at the company. In GARDEN they also use such kind of trolley. This trolley is use for the transfer of POY bobbin from one place to another. The trolley capacity is 24-36 rolls. In GARDEN they have approximately 900 to 1000 trolleys. As shown in the image the POY bobbins are kept in the stand which is fitted on the trolley.

FORK LIFTS

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Fork Lifts is very useful and very capable equipment. This is use to carry the very big or the jumbo boxes. These boxes are very big and heavy, so that it cant be ha ndling manually. So thats why the fork lifts are being used. This lifts can carry the boxes up to the height of 2 mts. This is use to load the boxes in to the truck. This lifts use diesel as fuel. We can see in the both image that, in the 1st image its shows the lifts and in the 2nd image it shows how this fork lifts work. PALLETS Pallets are also very useful equipments. This is useful to carry the jumbo box on it. As we know that jumbo box cant be handling manually, so these pallets are use. Pallets are made of plastic & wood. We can see the diagram of pallets. In the 1st image we can see different size of pallets and in the 2nd image we can see how the boxes are kept on pallets. These pallets are handled with the help of the Fork lifts.

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The supplies of box are done on pallets. Once the buyer gets his order he gives back these pallets to the company. In GARDEN they use the pallets made of wood.

HYDRAULIC MACHINES

This machines capacity is about 2000-3000 kgs. This equipment is used to carry the jumbo boxes. The jumbo boxes cant be carried manually, so because of that this kind of equipment is being used. It helps to make the dispatch of finished goods faster.

There are also some other things that can be used for material handling. These we cant

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say the equipment but it helps a lot to save the goods. These are as follows. Plastic Bags. Boxes. ( Small and Jumbo)

PROCESS OF MANUFACTURING

Different techniques, such as weaving, printing, dying, shrouding, packing etc. are used in the production process. Yarn is chief raw material of the company. It is not manufactured at the plant of Vareli but is manufactured for looms at Jolva. Process of production can be described as below: OBTAINING THE RAW MATERIAL STORING RAW MATERIAL TWISTING THE YARN TEXTURISING OR CRIMPING THE YARN DRAW WARPING SIZING WEAVING DYING AND PRINTING OBTAINING THE RAW MATERIAL :The raw material consumed by the company is Partially Oriented Yarn (POY). The yarn is procured from both internal and external sources. INTERNAL SOURCES:Internal sources of the company comprise the manufacturing plant of Jolva and material purchase from Surat Textile Mills (STM), Which is under the Garden Group of Company. Vareli plant also acquires raw material from Surat Textile Mills. EXTERNAL SOURCES:-

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In the peak season, if the internal sources are unable to meet the demand, the company also procures material from external sources like Modern, Indo-Rama, and Reliance etc. STORING THE RAW MATERIAL :-

All the raw material needed by the various departments is purchased together and maintained in the storage area called Dump Store from where any department can access the required amount of raw material. TWISTING THE YARN:

Parcel oriented yarn is either twisted, according to the requirements of material consumed in production.

Process of twisting:

a) Winding on bobbins: firstly POY is wound on bobbins, which are twisted on the twisting machine. The winding of yarn is done on the winding machine. b) Twisting machine: the POY wound on the bobbins is then tittled on the twisting machine. On which the yarn is twisted. In this process, first the yarn is passed through spindles on which the yarn is twisted in both the opposite directions One for one twisting machine: in this machine, the yarn is twisted once for revolution. Two for one twisting machine: in this machine, there are two twisters per one revolution. Now days, TFOs are more widely used as they are quicker and offer a better quality.

Fancy Twister: the yarn before twisting is not very strong and breaks easily. It is
twisted in order to increase its strength. Due to twisting, quality improves and hence production also increases.

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 TEXTURISING OR CRIMPING THE YARN: the POY is accessed from the dump store to the crimping or texturizing section to texturizing it. Denier is unit for measurement of POY. Those 9000 units of yarn are hanker and weighted in Gms, are called one denier. It is decreased after crimping.

Process of Crimping: Firstly, POY is put on machine in a specific amount. The place is called CRILL where it is put. After the first delivery, the yarn is heated. Then it is passed through cooling plate. After that, the yarn is passed through spindle assembly. Thereafter, it is passed through boiler and at all it is taken up. This is what the crimping to Texturizing process is. There are two ways for punching the yarn. I. Raito-punched or bound II. Crime-not punched Types of crimping machine: Friction type Magnetic type

DRAW WARPING:The POY is put directly on the Machine from the dump stove to draw warped process. Its the fully automatic system from the warping system. The process of drawing heat setting and intermingling is carried out. It is given tension and then wound on beam.

SIZING:Sizing is a process of saving of yarn. The raw material for sizing is accessed either from dump store, warp raw section or from texturising department. A beam is made at the beginning in the process on this department. Warp yarn i.e. Vertical threads are made

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A. WARPING. B. CHEMICAL PROCESSES: - Yarn is passed through a chemical called polyvinyl alcohol to find and arcyrize shining. C. WAXING: - Where the yarn is waxed. D. SIZING: - Sizing is made in this process which involves many chemicals as well as heading of cobbling processes. E. BEAMING: - Yarn is wound on a bean after sizing. Sizing which mean saving of yarn is necessary because of regular wear and tear.

WEAVING:After making the process of twisting camping, sizing or drawing warp, the yarn is rent to the weaving department. In grey cloth is manufactured through the process of weaving in this process one thread is horizontal and other is vertical. Horizontal thread is called Weft and the vertical thread is called Warp.

There are various types of looms on which the cloth is woven:1. SEMI AUTOMATIC LOOMS. 2. WATER JET LOOMS 3. FULLY AUTOMATIC LOOMS. It is notable that the production of grey cloth is 70000 mts/day and it increases every year. DYEING AND PRINTING:This is the lent step of the process of production department in the company. PROCESS:The jet dyeing process is widely used for dying the grey cloth. It is dyed printed according to the requirement of design and colors. A. First of all the grey cloth is washed and dyed, whichever color is necessitated. The

Company dyes 9000mts of cloth daily. B. The second step involves putting the dyed cloth in the drum washer to give crepe and

georgette crease effect along with washing the stains.

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C. The super wash machine is used for finishing and washing white color material. D. Salvage or border outing machine is used for border cutting of the cloth.

QUALITY POLICY OF GARDENS JOLWA PLANT

The Company follows the following slogan to show their quality preference

QUALITY IS TRUE BASIS OF VIABILITY

Company has adopted following points as a part of their quality policy:-

Satisfying customers need and expectation. Striving for continuous improvements through implementation of ISO 9001:2000.

Establishing, Communicating and Reviewing measurable quality objections. Developing and improving employee skills through effective training. Maintaining safe working practices.

QUALITY CONTROL SYSTEM

In GARDEN (JOLWA) there is a separate quality control department this department is besides of the production department. They check the quality of the R.M and Finished goods both. Their quality policy is to satisfy the customer at maximum level. The company has appointed many engineers who always take care about quality.

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QUALITY CONTROL FOR RAW MATERIAL & FINISHED GOODS

To make the POY the major R.M is POY chips and spin-finished oil. In GARDEN they always check the quality of this both. If they found any bad quality then they will keep it aside. They also safely load the material in to the machine.

Once the POY made they also check the quality of it. They check the quality of the entire POY bobbin. They take the sample from the each and every bobbin and then they make the sample cloth from it. Then they dyed and print that cloth. And if there is any mistake then they tell to production manager to solve it. If the quality is good then they put the symbol of OK tested and then they pack that material. They also check the denier and also the filament of the POY. The checking of denier is done with the help of the machine called Rap Reel Machine. And the checking of filament is done by computerized system.

QUALITY CONTROL FOR WORK-IN-PROGRESS GUIDELINE

In GARDEN they have also the system of checking the quality of goods when it is in progress. The experts keep their eye on the every activity of the machine. They check the every activity of machine. They have the computerized system in which they can easily know in which machine the problem is occurs. And then they solve it.

MAINTENANCE PLANNING SYSTEM

Maintenance is very important and necessary. In some company they use corrective maintenance or in some company they do regular maintenance.

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In GARDEN (JOLWA) they use the regular maintenance system. They do maintenance at every week. The maintenance officer checks all the parts of the machinery at every week. And in between if any problem occurs they suddenly try to solve it.

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DESIGN DEPARTMENT
There are 60 workers in design department under the direct control of the Chairman and M.D. and it is based at Surat with the assistance of CAD/CAN equipment, the department aims to produce up to 200 designs each month. Each design is available with number of different colors. These new designs are marketed for testing through selected dealers and depots, which is a contributory factor to a superficially high product return at 12 %. If the design fails to attract the customers, they are sold in spot sales of the company.

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DISPATCH
It may be defined as the process of setting production activities in motion through the release of work orders and instructions in accordance with previously planned schedules.

In every company they have the dispatch department. The function of this department is to dispatch the goods. The function of dispatching is more important in the intermittent production system and has less importance in continuous production system.

In GARDEN JOLWA the production system is the continuous. So, in this system the dispatch manager has to perform only few tasks. So, some functions of dispatch manager are as follows

1. To receive the pack goods from the production department and store in warehouse. 2. To receive the delivery order from the marketing department. 3. Arrange the goods as per the order. 4. Make the list of the boxes that will be dispatched. 5. To make challan. 6. To make invoice. 7. To give order to load the goods in the truck.

PROCEDURE OF DISPATCHING THE GOODS

The procedure of dispatching starts by receiving the order from the marketing department. So, steps in this process are as follows: 1. Marketing department give the order to the dispatch manager about what to delivered. This

report contains the name of the customer, quality he required, quantity required, etc This report looks like as follows:Number Name Code Grade DENIER Size of Total Rate

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box 1 Bhilosa Tex AAA SD 112/36 JUMBO

box 12 81.09RS/KG

2.

After receive the order from the marketing department now the dispatch

manager will

check whether the demanded goods are available or not. If available then they make list of that goods. And then they make challan from it. They make the three copies of the challan, from which one for them, another for buyer, and third take back from the buyer when he received the goods. 3. After making the challan they make the invoice. Invoice is the statement which shows the Invoice contains the following information: A. Buyers name. B. Consigners name. C. Delivery order no. & Date. D. Broker name & code. E. Mode of transportations. F. Vehicle no. G. Description of goods. H. Denier. I. Merge no.

total amount of bill. They also make three copies of invoice.

J. Grade. K. No of boxes. L. Total weight of goods in kg. M. Rate per kg. N. Total. O. Then taxes like VAT & EXCISE DUTY. P. Grand total or amount receivable. Q. Signature of the dispatch manager. Etc

4.

They make the three copy of invoice, from which they give one copy to

dealers. It is

useful for dealers when he go for payment collection. 5. After dispatching the goods the work of dispatch manager is being over.

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Now he has to file all the records safely for future use.

STORAGE DEPARTMENT

It is an extremely important cost that ever appears in accounting record. Components of this cost may be observed in several ways e.g. , in a profit making concern, sales lost as a result of stock out, or, there may be additional costs resulting from back ordering. Another component may be loss of goodwill due to delay in supply of finished goods. Sometimes, in production system, a part shortage may cause idle labour on a production line of subsequent incremental labour cost to perform operation out of sequence, usually at a higher than normal cost. Such type of costs may also be considered as a shortage cost. Industrial or institutional storage of material is also systematic & well documented. Because of this reason following expenses are incurred in storage of material.

WASTAGE CONTROL

In textile firm, avoidable waste is while we are wrapping the string on the scope we have to take care otherwise it wraps on here and there on the scope. It is the wastage of string. This cost is avoidable should be minimize or avoided.

In the textile field who is manufacturing the cloths while production process the role is wrapping on the bim through the wrapping machine. All the role are not empty after the string are wraps on bim some role contain a string are not used further because it is very less so production manager should not control this type of waste.

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49

ORGANIZATION STRUCTURE OF MARKETING DEPARTMENT

General Manager

Deputy General Manager

Senior General Manager

Assistant Manager

Programmer Manager

Dispatch Manager

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TYPES AND CLASSIFICATION OF PRODUCT

Product classification means differentiation between the products. The GARDEN JOLWA have also many kind of product related to POY. But the main product is the POY. This company produces all the type of different goods according to the demand of those goods. This company has the great market after the RELIANCE. The list of some product offered by the company and its annual sales volume is as follows:1. POY( PARTIALLY ORIENTED YARN) 2. TEXTURED YARN 3. DRAW TEX YARN 4. FULLY DRAW YARN
5. DRAW WINDER

PRODUCT MIX
PRODUCT CHIPS SARI MARBLE CHEEKS DRESS MATERIALS

POLYESTER NARA CHIFFON AMERICAN CHIFFON SETA CHIFFON

JAQUARD CDECLING

DECNINE BASSO

CHAIN SAREE

YARN HEARY OUT MARION

MARBLE CHIFFON PEACH SILK CREPS LENENS SETA CREORATTE

ULTRA SALEAN

SATVARLO LAPUR BLACK PERL ALFINE YOURY & CHERA

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A COMPLETE LABEL GIVES THE GARDEN SILLK MILL

Brand name Address of the product Gross & net quantity of the content Ingredients in the product Direction for the use Precautionary measures Nature of the product Date of packing Retail price

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EXPORT MARKETING

From Mumbai office the material is sent to foreign office Customer gives order at the foreign office Material is supplied to customer

SALES PROCEDURE

Sales procedure of each company differs from one another. Garden follows short length sales procedure as it constitutes only 1 middleman. All the sales of the products of the company are done only by the dealers only as they know the requirements of the customers. He negotiates with the customers and he gets all the information regarding the price which the customers are ready to pay and the total they want. In short, the dealer gives the complete information to the sales manager of the company about the customers. Following details are given by the dealers to the sales officer:1. Customer name 2. Quantity required 3. Quality required 4. Aggregate price The sales manager studies the details given by the dealer and if he is satisfied with the requirements of the customer and the price offered by him, then the procedure will start. The officer gives the reply to the dealers and the dealers ultimately give to the customers. If the company wants any change in its sales policy and price policy then the meeting is called of managers of all the departments and the opinion of each of them is taken into consideration and then the necessary changes in the side of the majority is taken. And whatsoever has been the decision, the sales manager will convey it to all the dealers. The procedure comes to and with the payment of the delivered goods and the customer has to give

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full payment and there is no policy of paying partly. The company follows its rule of payment and it does not change for any of its customers.

SOME NAMES OF THE COMPETITORS ARE AS FOLLOWS:-

1. RELIANCE SYNTHETICS. 2. GUPTA SYNTHETICS. 3. INDO-RAMA SYNTHETICS. 4. JBF INDUSTRIES. 5. MODERN PETROFILS. 6. NOVA PETROCHEMICALS. 7. CENTURY INKA.

INTERNATIONAL COMPETITORS: Garden Silk Mills Ltd operates in the Apparel and accessories sector. This analysis compares Garden Silk Mills Limited with three other miscellaneous apparel manufacturers in developing countries: Bata Chile SA of Chile (2000 sales of 68.25 billion

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Chilean Pesos [US$109.20 million]), Rex True form Clothing Company Limited of South Africa (289.10 million South African Brands [US$36.04 million]), and Buettner SA Industries Commercial which is based in Brazil (106.97 million Brazilian Reals [US$46.41 million]).

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A CERTIFICATE OF QUALITY CONTROL IS AS FOLLOWS

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