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PREFACE
We are going to make our project on textile industry in order to know the Manufacturing
process and Layout. This project also gives the some important information of textile industry
those brands, different product, New business, New technologies, New partnership. Because
technologies also shape corporate destines.
The Career of the Person depends upon many things. One of them is the knowledge. It
acquires through theory is not sufficient to develop. Her personality and to develop some skills,
but now a days, it is no more. Practical training is necessary to implement the theories & acquire
the knowledge, so for this purpose our institute Global Institute of Management affiliated by
Gujarat Technological University.
The report is made with clear objective of study of textile industry its working. The report
will give the details of Production .Our report provides you all the information related to
the Production. We hope this report fulfils need of the educational requirements.
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ACKNOWLEDGEMENT
We are heartily thankful to the Gujarat Technological University, which has given us the
golden opportunity to prepare or analyze project report of textile industry. We are also
thankful to honorable professor Ms.Anupama Ambujakshan who has leaded us to enlighten
ourselves in preparation of this project.
We are heartily thankful to Management Faculty without whose constant guidance this
work would have been an impossible task to complete. Her inspiration and encouragement has
leaded me to come with a successful task.
INDEX
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NO
1
2
PARTICULAR
PREFACE
ACKNOWLEDGEMENT
PAGE NO.
2
3
7-14
FACILITY LOCATION
15-19
20-22
23-27
BIBLIOGRAPHY
28
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Cotton Textile
Silk Textile
Woolen Textile
Readymade Textile
Hand-Crafted Textile
Jute And Coir
In the production system there are following types of production system can be used for the
conversion of raw material into the finished goods.
There is the different type of techniques used in the production process.
Project
Job shop
Batch production ( disconnected line)
Assembly line
Continuous flow
Cell manufacturing (group technology)
The textile industry using the JOB-SHOP or BATCH PRODUCTION techniques for the
production.
The Weaving Process Is Characterized By Long Planning Horizons And Relatively Slow Speed
Of Machines, Very Long Setup Times, Very Large Production Batches, And Mixed Order And
Stock-Based Production. On The Contrary, The Warp Making Process Is Characterized By Short
Planning Horizons And High Speed Of Machines, Short Setup Times, Small Production Batches
And Only Orders-Based Production. The Above Phases Pose The Most Complex Production
Scheduling Problems.
JOB-SHOP techniques:In the job shop machinery used mostly general purpose to produce the goods.
Highly skilled labor is needed for this type of production system to handle and operate the
machinery.
Production Is Characterized By Processing Of Small Batches Of A Large Number Of Different
Products Most Of Which Require A Different Set Or Sequence Of Processing Steps.
In the job shop technique i.e., print shop
Textile production systems may be treated as a succession of local problems, one per each
production phase. The coherence of these local problems should be taken into account by
material requirements planning or just-in-time approaches.
INTRODUCTION:Products are the goods and services produced and processes are the facilities, skills, and
technologies used to produce them. Production function or operation function is the primary
function of an industrial enterprise. It is also known as conversion process or transformation
process which transforms some of the inputs (raw material and components) into outputs which
are useful for the consumers.
INPUTS
CONVERSION
PROCESS
OUTPUTS
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MULE SPINNING
SPINNING
RING
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Cloth Is Usually Woven On A Loom, A Device That Holds The Warp Threads In Place
While Filling Threads Are Woven Through Them. A Fabric Band Which Meets This
Definition Of Cloth (Warp Threads With A Weft Thread
Winding Between) Can Also Be Made Using Other
Methods, Including Tablet Weaving, Back-Strap, Or Other
Techniques Without Looms.
DYEING:The Most Commonly Used Processes For Imparting Color To Cotton Are Piece Dyeing
And Yarn Dyeing.
In Piece Dyeing, Which Is Used Primarily For Fabrics That Are To Be A Solid Color, A
Continuous Length Of Dry Cloth Is Passed Full-Width Through A Trough Of Hot Dye Solution.
The Cloth Then Goes Between Padded Rollers That Squeeze In The Color Evenly And Removes
The Excess Liquid. In One Variation Of This Basic Method, The Fabric, In A Rope-Like Coil, Is
Processed On A Reel That Passes In And Out Of A Dye Beck Or Vat.
Yarn Dyeing, Which Occurs Before The Cloth Is Woven Or Knitted, Is Used To Produce
Gingham Checks, Plaids, Woven Stripes And Other Special Effects. Blue Dyed Warp Yarns, For
Example, Are Combined With White Filling Yarns In Denim
Construction.
A Typical Printing Machine Has A Large Padded Drum Or Cylinder, Which Is Surrounded By A
Series Of Copper Rollers, Each With Its Own Dye Trough And Doctor Blade That Scrapes Away
Excess Dye. The Number Of Rollers Varies According To The Fabric Design, Since Each Color
In The Design Is Etched On A Separate Roller. As The Cloth Moves Between The Rotating
Drum And Rollers Under Great Pressure, It Picks Up Color From The Engraved Area Of Each
Roller In Sequence. The Printed Cloth Is Dried Immediately And Conveyed To An Oven That
Sets The Dye.
Automatic Screen-Printing Is Another Principal Method For Imparting Colored Designs To
Cotton Fabrics. Although Slower Than Roller Printing, It Has The Advantage Of Producing
Much Larger And More Intricate Designs, Elaborate Shadings And Various Handcrafted Effects.
FINISHING:Finishing, As The Term Implies, Is The Final Step In Fabric Production. Hundreds Of
Finishes Can Be Applied To Textiles, And The Methods Of Application Are As Varied As The
Finishes.
Cotton Fabrics Are Probably Finished In More Different Ways Than Any Other Type Of
Fabrics. Some Finishes Change The Look And Feel Of The Cotton Fabric, While Others Add
Special Characteristics Such As Durable Press, Water Repellency, Flame Resistance, Shrinkage
Control And Others. Several Different Finishes May Be Applied To A Single Fabric.
CUTTING:The Fabric Is Then Cut With The Help Of Cloth Cutting Machines Suitable For The
Type Of The Cloth. These Can Be Band Cutters Having Similar Work Method Like That Of
Band Saws; Cutters Having Rotary Blades; Machines Having Reciprocal Blades Which Saw Up
And Down; Die Clickers Similar To Die Or Punch Press; Or Computerized Machines That Use
Either Blades Or Laser Beams To Cut The Fabric In Desired Shapes.
Sewing:It Is The Most Important Department/ Section Of A Garment Manufacturing Industry. Sewing
Machines Of Different Types Are Arranged As A Vertical Line To Assemble The Garments.
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PRIMARY ACTIVITIES
SECONDARY ACTIVITIES
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Unloading
Fork lifting
Unwrapping
Cutting Ties
Waste Bailing
Feeding
Removing Lint
Movement Of Card Cans
Movement Of Drawing Cans
GLOBAL INSTITUTE OF MANAGEMENT
Spinning Yarn
Warp Filling
Winding Yarn Onto Beam
Supplying Beams
Preparing Loom Beams
Storing Loom Beams
Hoisting
Producing Fabric Rolls
Inspecting Fabric
Cutting Fabric
Wrapping
Loading
SUPPORT ACTIVITIES
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Eating
Relaxing
Storage
Personal Hygiene
Supervision
Maintenance
Air Washing/Conditioning
Lint Removal
Quality Control
Testing
Training
Monitoring
FACILITY LOCATION
Plant location may be understood as the function of determining where the plant should
be located for maximum operating economy and effectiveness. The selection for locating
a plant is most important factor which influences the industry.
Any industry has try to locate their plant near by the market place, where transportation
facility available, labour force, raw material, poweretc
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Popularly Termed As The Textile State Of India, Gujarat Has One Of The Most Flourishing
Textile Industries In The Country. Also Said To Be The Manchester Of The East And The Denim
Capital Of India The Textile Industry In Gujarat Contributes Almost 3% Towards The GDP Of
India. India Holds A Major Portion Of Global Textile Market Share. Textiles In Gujarat Are
Responsible For Contributing A Major Share Of India's Art And Crafts.
It Is Also Among The Oldest Industries In The State. Due To Its Perfect Combination Of Skilled
Labor, Vast Variety Of Raw Materials, Seamless Blend Of Yarns And The Use Of Traditional
Techniques The State Produces The Finest Range Of Textiles.
One Of The Major Factors Behind The Success Of The Textile Industry In Gujarat Is That The
State Has Managed To Preserve Its Old Tradition And Culture.
The Textile Industry In Gujarat Involves Quite A Sizable Chunk Of The Population. Brands Like
Arvind Mills, Parag And Praful Belong To Gujarat. More Than 90% Of The Polyester Used In
India Is Produced In Surat. The Two Major Textile Manufacturing Cities In Gujarat Are
Ahmedabad And Surat. Both These Cities Together Account For Almost 50% Of The Total
Textiles Produced In Gujarat.
Textiles in Gujarat
BANDHEJ:Bandhej Is The Name Given To The Tie And Dye Fabric Of Jamnagar, Mandvi And Bhuj. The
Art Of Bandhej Is Known For Its Typical Designs And Patterns. These Are Often Used In
Wedding Outfits When They Are Called Gharchola Odhni And Sarees.He Tie-Dyed Fabrics Or
The Bandhej Of Gujarat Are Certainly The Best Of Its Kind Produced In India Also Lso Known
As Bandhani Or Bandhni.The Cost Of The Bandhej Of Gujarat Rests Not Only On The Quality
Of The Fabric, But Also On The Number Of Times It Has To Be Tied And Dyed As Well As The
Intricacy Of The Pattern.
MATANI:Matani Or More Popularly Called Matani Pechedi Or Mata-Ni-Pachedi Are Made By The
Vaghris For The Purpose Of Various Rituals. They Employ A Combination Of Block Printing
For The Outline Of The Pattern As Well As The Painting Of The Mordants.The Matani Is
Actually A Tribute To The Mother Goddess Durga.Matani Reflects A Passion Among The
Gujaratis For Colors And A Vision For The Intricate Designs And Forms. It Is The Expression
Of An Artistic Personality As Well As Rich Cultural Heritage.
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PATOLA:The Patola Silk from Patan Is Very Popular And One Of The Largest Selling Fabrics In The
Country. The Sarees Are A Mark Of Tradition And Grandeur Depicting Gujarat As A Land Of
Prosperity And Wealth. This Is Unique To Patan And Is Known For Its Utmost Delicate Designs
Woven With Great Expertise And Quality. Gujarat Patola Exhibits A Passion For Color And A
Deep Sense For Design And Form. They Convey A Message Of The State's Rich Cultural
Heritage.
The Indian Textile Industry Today Has Approximately 1200 Medium To Large Scale
Textile Mills In India. 20%Of These Mills Are Located In Coimbatore (Tamilnadu).
The Industry Has 34 Million Cotton Textile Spindles For Manufacturing Cotton Yarn
Which Account For 70 Percent Of India's Textile Exports. (China Has 40 Million Cotton
Spindles.)
Of The Indian Textile Yarn Exports, Almost 80 Percent Come From Coarser Yarns
(Counts Below 40's). Consequently, There Is A Need To Upgrade The Technology.
The Domestic Knitting Industry Is Characterized By Small Scale Units With Facilities
For Dyeing, Processing And Finishing. The Industry Is Concentrated In Tirupur
(Tamilnadu) And Ludhiana (Punjab). Tirupur Produces 60 Percent Of The Country's
Total Knitwear Exports.
Knitted Garments Account For Almost 32 Percent Of All Exported Garments. The Major
Players Include Nahar Spinning, Arun Processors And Jersey India.
EMPLOYMENT OPPORTUNITIES:The Indian Textile Industry of India is vast and growing with presence of several national and
international brands. The main segments of the Indian textile industry are Man-made Textiles,
Cotton Textiles including Handlooms, Silk Textiles, Woolen Textiles, Handicrafts, Coir,
Readymade Garments, and Jute.
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Job opportunities are diverse in nature in the textile industry ranging from production, designing,
distribution and sales. The need for manpower for the textile industry is growing to keep up with
the growing demand; freshers are finding numerous job opportunities in the textile industry of
India.
The Indian textile industry offers opportunities to fresher's from various academic backgrounds
as nature of job is diverse. A textile engineer must have an engineering background; either B.E.
or B.Tech is preferred
Indian Textile Industry Is Known To Be The 3rd Largest Manufacturer Of Cotton Across
The Globe.
This Industry Of India Claims To Be The 2nd Largest Manufacturer As Well As Provider
Of Cotton Yarn And Textiles In The World
India Holds Around 25 % Share In The Cotton Yarn Industry Across The Globe
India Textile Industry Contributes To Around 12 %Of The World's Production Of Cotton
Yarn And Textiles.
Size Of The
Industry
Geographical
Distribution
Output Per Annum
Percentage In
World Market
Market
Capitalization
The
need for the
selection of the location may arise under any of the following conditions:1) When the business is newly started;
2) The existing business unit has outgrown its original facilities and expansion is not
possible;
3) A lease expire and the landlord does not renew the lease;
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4) Other social or economic reasons; for example inadequate labour supply, shifting of
the market.
STEPS IN LOCATION:in choosing a plant location, the entrepreneur would do well to proceed step by step,
the step being;
1) Within the country or outside;
2) Selection of the region: Availability of raw material
Nearness to the market
Availability of power
Transport facilities
Suitability of climate
Government policy
Competition between stat
Process Layouts Require The Most Movement Of Products From Workstation To Workstation
Since The Equipment Is Arranged Without Regard To The Processing Needs Of Any One
Product. Job Shops Can Attempt To Reduce This Unnecessary Handling, However, By Assessing
Movement Between Various Workstations For Each Product. They Can Then Determine The
Total Number Of Product Movements Between Workstations For All Of Their Products And
Arrange The Different Process Areas To Reduce The Total Number Of Product Movements.
Process Layouts Do Have The Advantage, However, Of Maximizing The Efficiency Of
Machinery Usage. All Products Requiring Drilling, For Example, Are Moved To The Same Drill
Press. Therefore, The Total Number Of Drill Presses Required Is Kept To A Minimum.
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Unlike Process Layouts, However, Product Layouts Maximize The Need For Expenditures On
Equipment. Studies Have Shown That Savings In Process Efficiency Far Outweigh These
Additional Machine Costs. If Cutting Stations Are Required At Several Steps Along The
Processing Route, Product Layouts Would Require Purchasing Separate Saws For Each Step To
Allow The Uninterrupted Flow Of Work Along The Line.
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CHEMICAL SAFETY
RESPONSIBILITY
Role of The Management
Role of The Factory Staff
Substances used directly in work activities (e.g. adhesives, solvents, cleaning agents);
Substances generated during work activities (e.g. fumes from soldering and welding);
Naturally occurring substances (e.g. dust); and Biological agents such as bacteria and
other micro-organisms.
An inventory and risk assessment of all chemicals and dyes that are present at the factory must
be undertaken by the management. The MSDS simplify this process by providing much of the
information required in this risk assessment. The risk assessment should consider how chemicals
are stored and handled. The information in the inventory and risk assessment must be made
available to all workers. The factory management team should remove unnecessary risks and
protect against those that remain. The steps involved in undertaking a risk assessment include:
Reference to the suppliers MSDS;
Observations at the factory (on the production floor, in the laboratory and in the
chemical store);
Consultation with employees and supervisors; and
Assessing feedback and results from monitoring of potential health risks.
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There Should Also Be Signs Saying No Food And Drink In Areas Such As The
Laboratory, Store Room And Factory Floor, And Any Other Areas Where It Is
Not Safe To Consume Food, For Example Because Of The Risk Of
Contamination By Chemicals.
Hazardous Chemicals Should Be Clearly Marked In An Appropriate Language
And With Clear Symbols That People Have Been Trained To Recognise And
Understand.
Heavy Objects Should Be Marked As Such To Avoid Musculoskeletal Accidents.
Substances Or Items That Present A Fire Hazard Should Be Clearly Labelled
With The Universally Recognized Symbol.
Signs Should Be Placed Near Inflammable Substances Stating That It Is Not
Permitted To Smoke Or Have Open Fires.
Showers And Eye Washes Should Be Made Available And Clearly Marked.
Report Any Defects Or Problems With The Machinery That Might Lead To Potential
Accidents.
BIBLOGRAPHY
BOOK:- 1) operation and supply management 12th edition
2) Production and operation management (k.aswathappa Himalaya publishing house)
Websites:-
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www.cci.in
www.Rabatex.in
www.alok.in