Jagdish Bhanderi Altamash Nadab

Nirav Gupta
Anjali Agarwal Madhuri Chhipa

Content
Production process Comparative analysis

Objectives

Production and production process

Raw materials

Welspun syntex limited

Asphra textiles limited

 To understand the production process. To accept a unique opportunity to gain an insight into a working environment related to a subject area. To examine text book knowledge with the practical environment. To gain first hand information regarding functioning of the Industry. To become aware of the role of different people in an organization.

WELSPUN SYNTEX LIMITED

31 Mar.'83 as Kothari Leasing Kothari Polyesters on 15 Mar.'91 Welspun Syntex (WSL) on 26
Jul.'91. Public (BSE: 508933) Textile processing Mumbai BK Goenka (MD), BA Kale Director & CEO) Welspun Group Silvassa and Palghar Rs 3, 6113 lacs (2009-10).

PALGHAR PLANT
Palghar, a small town 80kms north of Mumbai. Welspun started its first manufacturing activity. Today, Palghar Plant houses one of the most advanced dyeing plants of polyester, nylon yarns in India. Palghar plant enjoys the advantages of ideal geographical location to efficiently handle all the logistics to facilitate prompt shipments to the Indian and overseas customers. The product range and process parameters are designed to optimize the production capacity and minimize the cost of production without compromising on quality and offers the best value for money.

An profit making dyed yarn manufacturing company. Manufactures -texured synthetic and cotton dyed yarn Established -1998 Location -Mumbai and Palghar. Market position - The Company has dominant presence in India with its own sales brand Consuming centers -Bangalore, Mumbai, Bhilwara & Panipat.

PRODUCTION PROCESS
Mechanical or chemical steps used to create an object, usually repeated to create multiple units of the same item. Generally involves the use of raw materials, machinery and manpower to create a product.

RAW MATERIALS
The raw materials used are as follows

Polyester Filament

Cotton Filament

Dyes

Conning Combing Spinning Twisting Hydro-wash Hydro-extract Drying Rewinding

Checking
Packaging

In this stage the filament is transferred from paper cones to iron cones fixed in the machine.

Combing provides more extensive cleaning. Combing provides more extensive cleaning.

The purpose of combing is to remove short fibers, neps and trash so that the resulting sliver is very clean and lustrous.

Polyester Partially Oriented Yarn, commonly known as Polyester POY is the primary form of Polyester yarn. It is the first form of yarn made directly by spinning Polyester PET Chips/Flakes.

Spinning is the single most costly step in converting fibre to yarn.

The filaments are twisted to add stretch and elasticity which produces the polyester yarn.

Dyeing is the process of adding color to textile products like fibers, yarns, and fabrics. Dyeing is normally done in a special solution containing dyes and particular chemical material. The temperature and time controlling are two key factors in dyeing.

After dyeing

The dyed yarn packages are put in Hydro Extractor which removes moisture by the centrifugal process.

Dyed yarn is taken up for rewinding on paper cones ,which also has a facility of waxing as the optional facility for the Customer.

Dyed yarn on paper cones is again conditioned and then finally each individual cone is checked for any quality defects by visual inspection under light and then it is packed for shipment

The so formed POY is then exported to countries like Malaysia, Sri lanka, brazil middle east.

WAREHOUSE

A warehouse is a commercial building for storage of goods.

Welspun Syntex limited

Asphra textiles limited

Scale of production
Large scale i.e. 1400 tons a month Small scale i.e. 70 -80 tons a month0

Works for 24 hours

Works for 12 hours a diurnal

1000+ workers

120 workers

Production system
Process production

Batch production

Plant layout
Process layout Product layout

Maintenance system
Total productive maintenance Preventive maintenance

Product design
Research and development Customized