1. Department: BLOW ROOM

Process flow chart:

INPUT: Cotton Mixing

PROCESS: The purpose of blow room process is to open, removal of heavier impurities present and clean the cotton and make it a continuous sheet with uniform predetermined weight per unit length. It is wound on a lap rod for feeding to the carding.

OUTPUT: Lap weight = 23 kgs (including lap rod)

Length = 49mMACHINE:

2. Department: CARDING

Process flow chart:

INPUT: Blow Room lap

PROCESS: During carding process the blow room lap is opened, cleaned and neps are removed, fibers made parallel & individualized, required amount of waste is extracted and assembled in the form of sliver with a uniform predetermined weight per unit length and collected in a can in a coiled form for feeding to sliver lap machines.

OUTPUT: Card Sliver

MACHINE:

INPUT GBR AXIFLOW STEP CLEANER VISION SHIELD SHIELDSHIELD

MULTI MIXER SCUTHER OUTPUT

INPUT FEED ROLLER LICKER-IN CYLINDER DOFFER

OUTPUT

3. Department: SLIVER LAP

Process flow chart:

INPUT: Card Sliver

PROCESS: During the process of sliver lap, a definite no. of card slivers are doubled, drafted and wound as a sheet of lap with uniform weight per unit length on a spool for feeding to ribbon lap machine.

OUTPUT: Sliver Lap

MACHINE:

4. Department: RIBBON LAP

Process flow chart:

INPUT: Sliver Lap

PROCESS: During ribbon lap process a definite no. of sliver lap machine laps are doubled, drafted and wound as a sheet of lap with uniform weight per unit length on to a spool for feeding to comber machine.

OUTPUT: Ribbon Lap

MACHINE:

INPUT CREEL DRAFTING ZONE OUTPUT

INPUT LAP STAND DRAFTING ZONE FEED TABLE

OUTPUT

5. Department: COMBER

Process flow chart:

INPUT: Ribbon Lap

PROCESS: The object of cotton combing is to remove short fibers, minute impurities, neps & fibers made parallel & assembled in form of the sliver. No. of such slivers are drafted and stored in cans in the form of sliver. The sliver has definite weight per unit length & collected in a can in coiled form for feeding draw frames.

OUTPUT: Comber Sliver

MACHINE:

6. Department: DRAWING

Process flow chart:

INPUT: Comber Sliver

PROCESS: The purpose of drawing process is to double a definite no. of slivers & drawn them together to make the sliver more even & parallelize the fibers. The sliver is stored in cans or coiled form for feeding to simplex machines. Auto leveling on weight per meter is tacking place while passing through the machine.

OUTPUT: Drawing Sliver

MACHINE:

INPUT CREEL SCANNING ROLLER ROLLER

DRAFTING ZONE

OUTPUT

INPUT FEED ROLLERS COMBING ZONE FEED TABLE

DRAFTING ZONE OUTPUT

7. Department: SIMPLEX

Process flow chart:

INPUT: Drawing Sliver

PROCESS: The object of simplex or speed frame process is to attenuate the finisher draw frame sliver into a finer strand, twist and wind it on a plastic tube suitable for feeding to ring spinning machines.

OUTPUT: single/double yarn

MACHINE:

8. Department: AUTOCONER WINDING

Process flow chart:

INPUT: Single/Double yarn

PROCESS: In the autoconer winding process yarn from ring spinning/doubling etc. in cop form fed and converted into a cone package of definite weight per unit length during this winding process. The objectionable faults in the yarn are removed by electronic yarn checker (EYC). The cut ends are joined by a splicer & taken onto cones as a continuous length of yarn. The yarn may be waxed, if required, during this process.

OUTPUT: Yarn in cone form

MACHINE:

INPUT CREEL DRAFTING ZONE FLYLER WIND ON

BOBBIN OUTPUT

INPUT MAGAZINE COP HOLDER EYC (With (OR) without contamination clearing)

PAPER/PLASTIC CONE OUTPUT

QUALITY POLICY

GTN IND. Ltd would achieve the highest level of customer satisfaction

by their stated & perceived requirements, maintaining consistency &

timely delivery.

GTN Endeavours continual upgradation of product quality &

technology supported by R&D efforts in a cost-effective manner.

To meet the changing global demands & stay ahead in competition.

GTN would adapt/innovate methods in its manufacturing activity.

GTN would inculcate a sense of quality awareness at all levels by

using appropriate training and motivation techniques.

GTN would aim at preserving the environment conditions by adapting

eco-friendly measures in its manufacturing & other activities.

PURCHASING PROCESS:

1. Selecting the suppliers depending upon the ability to supply the product

with organization requirements.

2. It also includes criteria for selection, evaluation, re-evaluation.

3. Records of supplier evaluation, rating & the necessary follow up action.

PURCHASING INFORMAYION:

Org have documented information to describe product to be purchased include

require for approval, required for qualification of personnel, where necessary &

other related information.

The documentation also specifies the need for ensuring adequacy

of specified purchasing information before placing order with the supplier.

Verification of PURCHASED PRODUCT:

The organization has documented the methods for verification of incoming

products. The type and level of verification may vary depending upon the effect

of the purchased product on sequent product realization or the final product.

In case the organization required to perform verification at the

supplier’s premises, the necessary verification arrangements are previously

agreed upon including the methods of product release.

IMPROVEMENT:

The organization Endeavour to continually improve the effectiveness of

QMS(Quality management system) through the following.

Quality policy & objectives

Internal quality audit results

Analysis of data

Corrective and preventive actions

Management reviews

Customer feedback reports

CORRECTIVE ACTION:

The organization established a procedure to deal with corrective action to

eliminate the cause of non-conformity.

This “intern alia” include review of non-conformities, determining

the cause of non-conformities evaluating the need for action to ensure these do

not occur, determining & effectively implementing the actions and recording the

actions taken.

Actions taken are reviewed for effectiveness.

INTERNAL COMMUNICATION:

The organization realizes that internal communication plays a vial role ensuring

the smooth & effective functioning of the QMS. The organization ensure that

information required to be communicated to persons who need to have then are

effectively done. A separate procedure addressing the means for this has been

established.

MANAGEMENT REVIEW:

The management of the organization conduct management reviews once in

every month. The reviews ensure that the system is effectively functioning , is

suitable adequate & serves the purpose in view. The review also addresses the

opportunities for improvement as may be brought in from different

levels/functions. The management review meetings are recorded & actions

initiated by concerned persons.

QUALITY MANUAL

CUSTOMER NEED

MANAGEMENT RESPONSIBILITY

RESOURCE MANAGEMENT

PRODUCT REALIZATION

MEASUREMENT ANALYSIS & IMPROVEMENT

CUSTOMER SATISFACTION

CONTINUAL IMPROVEMENT OF THE QUALITY MANAGEMENT SYSTEM

PRODUCT

HUMAN RESOURCE DEPARTMENT:

The organization employs personnel who are competent judged on the

basis of appropriate education, skills & experience in performing affecting

product quality.

Competence, Awareness, Training:

Organization provides training to fill the gap in knowledge/skills & evaluate

effectiveness of such training. It arranges to induct knowledge across the board

to all levels of employees, the importance of their activity & its contribution to

enhancement of quality of the product/process.

The organization maintains the records of training imparted

including imparted skills, experience, competence etc.

Infrastructure & Work Environment:

The organization have assessed and provide necessary infrastructure for

working to ensure conformity of product. These include equipment/machinery,

work environment, safety requirement as applicable, support services such as

transport, communication equipment etc.

Manufacturing process of SINGLE YARN

SAFETY MEASURES IN THE INDUSTRY

COTTON OPENING

MIXING

BLOW ROOM

CARDING

SLIVER LAP

RIBBON LAP

COMBER

DRAWING

SIMPLEX

RING SPINNING

AUTO CONER

PACKING

DELIVERY

PRECOMB MIXING

SUPER LAP

MIXING

BLOW ROOM WITH BLENDOMAT

CARDING WITH CHUTE FEED

In GTN industries safety is the major concern in every part of the

work .The industry also implemented the safety precautions in every

department .

Providing safety equipment for the workers in different sections for their

health safety.

In the industry there is a fire preventing alarm and fire preventing water

facility is also provided.

For every machine a board is attached which guides how to work on the

machine, to protect themselves from the hazards.

Management also giving awareness to the workers through the fire

preventing boards, and writing boards.

Every department is provided with a first aid box.

WASTE RE-USE:

In GTN industries the waste occurred is 28%, utilization is 70%, invisible loss is

2%. In the industry different approaches are defined for treating the waste. The

waste collected from different sections like BLOW ROOM, CARDING,

COMBING, SIMPLEX, RIBBON LAP, SLIVER LAP etc are contaminated in the

wasting section.

There are 9 types of waste collected which are as follows

1. Gutter

2. Cylinder Fly

3. SWP(sweeping) waste

4. Dropping no.

5. Hard waste or Yarn waste

6. Comber noil

7. Flat strips

8. Licker in fly

9. Roving ends

The collected waste from different sections is packed by using WASTE BALE

PACKING MACHINE.

WASTE RE-USE:

For the utilization of waste there are two types of waste are classified

SALABLE Waste

USABLE Waste

SALABLE Waste: The waste which is not used for the production is called

SALABLE waste. This waste is sell to the local manufacturers for different

purposes.

Example:

COMBER waste is used for surgical cotton

FLAT STRIPS is used for bedding

HARD WASTE is used for cleaning purpose, automobile cleaning

USABLE Waste: The waste which is suitable for the production purpose is called USABLE waste.

YARN Testing:

Electronic Wrap ReelBrand: STATEX

Test Procedure::

Reels up to 10 yarn skeins

Number of revolutions can be preselected from 1 to 200 by the operator

through keyboard with LED display

The reel starts gently and smoothly to increase normal speed under

microprocessor control, before reaching the preselected measuring length,

it slows down and approach the end of the measurement slowly and stops

at accurate position, which ensures uniform winding without any stretch

Stainless steel reel for accurate length measurement and better stability

Separate yarn stand is provided to accommodate 10 cops

MODEL E1.5/10C E1.5Y/20C E1M/10C E1M/20C

Reel

circumference 1.5 YARDS 1.5 YARDS 1 METRE 1 METRE

No. of skein

yarns 10 20 10 20

It is designed for adjustable pre-tension mechanism facilitates tension as

per ASTM standard to suit individual yarn through common selector. This

advanced pretension mechanism ensures uniform tension throughout

winding

ORGANOGRAM

VCMD

CE-Hyd

VP(P) VP(w)&MR

MGR(Prog AGM(c)

DM(P)-RD

SR.M(OA) DM(P)

M (PRD)

DGM(P&IR) SR.GM(RM&SP)P)P

GM(IT) SR.M (E)

Civil Supervisor

JR.off store

SUPER

JOBBER

HELPER

OPERATOR

DMM

Foreman

Sup.MT

FITTER

Asst.FITTER

HELPER

SUPR (PKG)

DM (OA)

AM (QA)

QA (Asst)

SUPERVISORS

MAISTRY

OPERATORS

OFF (RM)

ASST

AM(IT)

ASST

AMEEE

Foreman

Electrician

MT.Personnel

MRKT office SGM (M) DGM(M) DM(M)

OFF logistic

Personnel Asst M(C) Cashier

Mgr.Pers

SR.SUP

DM (P)

SECU

TKP

STENO

RECPT

FIBER TESTING:

USTER HVI SPECTRUM:Brand: USTER

PROCEDURE:

In this instrument except Trash and Neps all the parameters are checked.

For the measure of micronaire study 10gm sample is collected for the

testing.

The USTER HVI SPECTRUM provides with the required information of

Standard measurements of fiber length, uniformity, strength, micronaire,

color and trash to assist in selecting the right cotton for end product

Growers, ginners, traders and spinners specify, evaluate and select cotton

according to the quality standards of USTER HVI – the

only accepted standard worldwide.

The USTER HVI SPECTRUM is the only HVI instrument that is

Equipped with a patented moisture probe. Knowing the moisture

Content of the cotton at the time of testing.

The USTER BALE MANAGER is software provides information about the

cotton quality, allows customization for the bale selection process, and

stores historic information on laydowns that have already been consumed.

YARN Testing:

USTER TENSORAPID:

The USTER TENSORAPID gives all the known measured values in

tensile testing and offers improved analysis of the yarn quality. The results

determine the tested yarn’s suitability for knitting or weaving.

The software package with USTER TENSORAPID calculate the following

additional characteristics:

• Elasticity-tension behavior of yarns

• Yield point definition by either strength or stretch

• Retardation and relaxation tests

A range of specially designed clamps and accessories guarantees

optimal, reliable and reproducible testing of yarns, hanks, slivers and also

fabric strips.

The clamps can be arranged horizontally or vertically, depending on the

material being tested. With a horizontal clamping position, the danger of

clamp breaks with critical yarns can be avoided, since a considerable

percentage of the stress will be absorbed by the frictional surface.

Electronic Twist Tester:

Brand: STATEX

Electronic Twist Tester is used to test single yarn and double yarn. Specimen

length adjustable from 0 to 20 inch or 0 to 50 cms.

Procedure:

Provision to test S and Z twist

Results are displayed in TPI and TPM. Minimum number of control

switches for complete use

It is used to test heavy yarns and Multi twisted yarns

Scale provided to measure elongation of test results

Automatic counter start/stop using optical sensor

Pre-tension weight available up to 250 grams

Suitable for both Microprocessor Twist Tester and Electronic Twist Tester

QUALITY ASURANCE Department

In the quality assurance department testing of the fibers, hanks, and yarns is

done for the end product quality .It includes three stages they are,

1. Incoming inspection

2. Process control inspection

3. Final inspection

1. INCOMING INSPECTION: Incoming inspection includes the raw

materials, stores, materials, i.e. incoming goods are inspected thoroughly so, that

no faults can’t be occurred in the product with the raw material or with machine

etc.

2. PROCESS CONTROL: DEM Process approach is used in the GTN industries

DEM cycle approach

3.

FINAL INSPECTION: Final inspection include the testing of hank ,fiber and

yarn .every processing element like carding ,combing, simplex etc.is undergoes

into checking whether it is acquired quality according to the specification . Fibers,

hanks, yarns are tested by using different Instruments. The results of the testing

instruments used by GTN industries are accepted by worldwide.

Environment for Q&A Dept.:

650– RH (relative humidity) - -2250 - TEMP - ±2

In the quality assurance department the parameters of yarn checked Are as follows

COUNT

STRENGTH

CSP (Count Strength product)

ELONGATION

CMT ( classimate faults in yarn)

CV (count variation)

PLAN ACT

DOCHECK

IMPERFECTION

I. Thin Places 2. Thick places 3. Neps

There are three types tests taken in the Q&A Dept

Fiber testing

Yarn testing

USTER CLASSIMAT QUANTUM:

PROCEDURE:

By using USTER CLASSIMAT QUANTUM We can check cleared

and uncleared yarn, providing perfect classification of thick and thin

places, as well as checking infrequently occurring yarn defects and,

recently, foreign fibers in the yarn.

Classifying foreign fibers into 27 classes according to

the FOREIGNCLASS classification system which is recognized worldwide.

USTER CLASSIMAT QUANTUM allows the distinction to be made

between organic and non-organic foreign matter

Defining customized classes allows targeted monitoring of individual faults

in the desired size, for thick and thin places as well as for foreign fibers.

Determining infrequently occurring yarn faults in 23 classes of thick and 4

classes of thin places.

USTER STATISTICS Compare measuring results with the international

quality benchmarks directly on the screen.

BALANCES&WEIGHING SCALES:

Brand: AFCOSET

PROCEDURE:

Afcoset balances are peerless in accuracy and reliability.

Selectable weighing modes Kg, counting or percentage.

Large and easy read out display mounted on tall column

Outstanding Accuracy up to 1/10000 displayed count resolution.

Optional RS232 allows connection to computer.

PACKAGING Section:

In the packaging section cones which are wounded on auto coner are

taken for packaging.

Every cone will be checked under UV lamp, if any fault found it is removed

again rewounded.

Faults include oil marks, waste attached, and mixing of different counts in

the yarn.

12 cones are packaged in one box. Cones are first packed with polybag

and next in the gunny bag and put in the company logo box.

Every box consists of following information

ORDER NO. , COMPANY, COUNT, LOT NO. , COUNTRY

ORDER NO.: It is order no of the buyer given by the company GTN.

COMPANY: To the company whom they are manufacturing for

COUNT: Count of the cone

LOT NO.: It is lot no. in which the yarn is manufactured

COUNTRY: where the company is exporting to

1.ELECTRICAL Daily Weekly Fortnightly Monthly Quarterly

Yearly

Machine voltage √ Main contactor I/O

√Auxiliary contactor I/O √Computer input I/O

√Motor input amps √2. OIL FUNCTION NOZZLESOil level √oiler √Cylinder bed √Dial set √QAP Drive set √Take up set √3. HEATMotor √Cylinder/Dial cam box

√4. AIR

Air pressure √ Air moisture √5. Tightness Cylinder/dial cam box screws

√ Cylinder cam box holder screws

√Cams screws √6. CLEANING POINTMachine √Panel board √Panel exhaust fan √Inverter cooling fan

√Oil tube& nozzles √Cylinder &dial cam box

√Take-up roller √MPF storage feeder

√7.OIL&GREASE REPLACEMENTCylinder & dial bed

√QAP set oil √TAKE-UP set oil √TAKE-UP set grease

√8. CLEARNCECylinder to cylinder cam box

√Cylinder to sinker cam box

√

*Preventive Maintenance for KNITTING MACHINES

Maintenance of knitting machinery:

The machine breakdown is 0.06% in the GTN in industries.

PREVENTIVE MAINTENANCE helps for less breakdown of machinery

For the newly purchased machine 3-4 years there is no maintenance

problem

Only older machines undergoes for the maintenance activity

MAINTENANCE DEPT. takes care of the maintenance of machinery, it

purchases all the material required for the machinery.

MAINTENANCE DEPT. prepared for frequent and emergency breakdown

of machinery.

Layout of KNITTING Section:

.EXIT

TESTING Section

FLAT KNITTING MACHINES

OFFICE GODOWN

AUTO STRIPER Thread Wounder

FLAT KNITTING Machine

RIB

INTERLOCK

MINI JACQUARD

SINGLE JERSEY

AUTO STRIPER

SINGLE JERSEY

SINGLE JERSEY

FULL JACQUARD

EXIT

Properties of cotton fiber:

1. Length

2. Uniformity

3. Fineness

4. Strength

5. Elongation

6. Maturity

1.Length

2. Uniformity

UNIFORMITY Index

Below 77 Very low

77 - 79 Low

80 - 82 Average

83 - 85 High

Above 85 Very high

LENGTH

Below 0.99 Short

0.99 – 1.10 Medium

1.11 – 1.26 Long

Above 1.26 Extra long

3.

Fineness

4. Strength

Fiber STRENGTH

20 and below Very weak

21 - 25 Weak

26 - 29 Base

30 - 32 Strong

32 and above Very strong

5. Elongation

Fiber FINENESS

Fineness(millitex) Description

Below 135 Very fine

135 - 175 Fine

175 - 200 Average

200 - 230 Coarse

Above 230 Very coarse

ELONGATION (%)

Below 5.0 Very low

5.0 – 5.8 Low

5.9 – 6.7 Average

6.8 – 7.6 High

Above 7.6 Very high

6. Maturity

Fiber MATURITY

Maturity Ration Description

Below 0.7 Uncommon

0.7 – 0.8 Immature

0.8 – 1.0 Mature

Above 1.0 Very mature

Defects in COTTON Fiber:

1. Micronaire

2. Immature cotton

3. Short fiber

4. color

1. MICRONAIRE: A numerical value that describes relative fiber fineness

and is derived from the micronaire method test which measures the

resistance of the fiber to a flow of air forced through it.

Micronaire must be controlled to prevent other defects like,

Barre, Warp streaks, Filling Bands, Strength variation, Efficiency loss.

Micronaire must be controlled

With in a laydown

<12.0% cv

Between laydowns , <0.2 Micronaire

<0.1% change in mix to mix Avg

2. Immature cotton:

Cotton is by nature…..

A raw material with many variations.

Maturity is one of those variable

Properties.

®®

Effects of Immature fibers:

Tend to reduce yarn strength.

Increase ends down.

Increase imperfections in yarn.

Cause reduced or variations in

dye uptake.

3. Short Fiber:

4. Color:

Cotton Color Affected By:

Rainfall

Temperature

Insects

Fungi

Staining from soil, weeds, grass

Storage conditions

Defects of YARN:

There are two types of yarn defects are defined they are as follows

YARN faults

Frequently Occurring Faults Randomly Occurring Faults

1. Frequently occurring faults

Thin Places

Thick Places

Neps

2. Randomly occurring Faults

Long Thin

THIN Places THICK Places NEPS LONG THIN LONG THIN

Long Thick

USTER TESTER Testing chart

Test no.

Um(%) CVm(%)

CVm(1m)

CVm(3m)

CVm(10m)

CVm(50m)

CVm(100m)

Thin places(-30%)

Thick Places(-40%)

Thin places(-50%)

1.

2.

3.

Mean ValueCVb(%)0.95% +/-

Thick Places(+70%)

Thick Places(+100%)

Neps(+140%)

Neps(+200%)

Neps(+280%)

Neps(+400%)

Rel. Count

(%)

Mean ValueCVb(%)0.95% +/-

USTER TENSORAPID Testing chart:

Time to Br.(S)

B-Force (cN)

Elongation(%) Rkm(kgf*Nm)

B-Work(cN.cm)

Test1Test2Test3 Overall ResultsMean ValueS +/-CV%Q95% +/-Min. valueMax.Value

USTER HVI SPECTRUM:

Bale ID

SCI Grade Mic Mat Len Amt Unf SFI Str Elg Moist Rd +b C Grade

CNT

MEAN: STD DEV: % CV:

Total no. of samples

USTER AFIS:

Rep Sample size(g)

Nep Cnt Mean size(mm)

Neps/gram

1. 2. 3.MeanSt. dev%CV

USTER CLASSIMAT QUANTUM:

USTER AFIS:

Analyzing and tracking the frequency, number, and size of neps from one

processing stage to another is a vital quality control tool for optimizing

Spinning conditions

USTER AFIS provides valuable information on how certain cottons

Will react to the different processing stages.

The AFIS Maturity module was developed to measure values and the

distribution of fiber maturity and fineness

Improved reliability and efficiency of machinery settings

Reduced maintenance costs

Neps:Analyzing and tracking the frequency, number, and size of neps from one

processing stage to another is a vital quality control tool for optimizing

spinning conditions

Measurements include:

• Neps

• Seed coat fragments

Length and maturity:

Length and short fiber content:

Fiber length information is necessary for a spinning mill to operate

efficiently and to consistently produce a quality product. Critical processes

that create and control the quality of cotton sliver must be monitored and

controlled on a regular basis.

Measurements include:

• Percent of short fiber content by

number and by weight

(>.50 inches/ 12.7mm)

• Length by number and by weight

• Coefficient of variation of fiber

length by number and by weight

• Upper quartile length by weight

• 5.0% length

Maturity:

The AFIS Maturity module was developed to measure values and the distribution

of fiber maturity and fineness. Immature fibers in raw material are the major

cause of white specks and barré in dyed and finished fabric.

Measurements include:

• Fineness (millitex)

• Immature fiber content%

• Maturity ratio

Trash and dust:

Cottons from different growth areas exhibit various amounts and sizes of trash

particles and require different degrees of cleaning in given growth

areas. USTER AFIS-T provides valuable information on how certain cottons

will react to the different processing stages.

Measurements include:

• Distribution of the size of trash and

dust particles (histograms)

• Number of dust and trash particles

per gram

• Percent content of foreign

matter (dust and trash)

Quality benefits

· Reduced or eliminated fabric barré

· Reduced short fiber content

· Reduced neps and seed coat fragments

· Improved reliability and efficiency of machinery settings

· Reduced maintenance costs