objective of internshipTo understand the concept of spun yarn production, grey fabric production, dyeing and finishing of fabric, textile testing & their quality aspects for both technical as well as for commercial purposes.The internship was carried out on the following assignment topics: Assignment I (Observations to be made and information to be documented on the Yarn manufacturing and winding section) Assignment II (Observations to be made and information to be documented on the weaving section) Assignment IV (Observations to be made and information to be documented on the Dyeing section) Assignment VI (Observations to be made and information to be documented on the Testing and Quality control sections)
ABOUT VARDHMANVardhman Group is a leading textile conglomerate in India having a turnover of 4500 CRORE. Spanning over 24 manufacturing facilities in five states across India, the Group business portfolio includes Yarn, Greige and Processed Fabric, Sewing Thread, Acrylic Fibre and Alloy Steel. Vardhman Group manufacturing facilities include over 8,00,000 spindles, 65 tons per day yarn and fibre dyeing, 900 shuttle less looms, 90 million meters per annum processed fabric, 33 tons per day sewing thread, 18000 metric tons per annum acrylic fibre and 100,000 tons per annum special and alloy steel.Vardhman has evolved through history from a small beginning in 1965 into a modern textile major under the dynamic leadership of its chairman, Mr. S.P.Oswal. His vision and insight has given Vardhman an enviable position in the textile industry. Under his leadership, Vardhman is efficiently using resources to innovate, diversify, integrate and build its diverse operations into a dynamic modern enterprise.MISSONVardhman aims to be world class textile organization producing diverse range of products for the global textile market. Vardhman seeks to achieve customer delight through excellence in manufacturing and customer service based on creative combination of state-of-the-art technology and human resources. Vardhman is committed to be responsible corporate citizen.
QUALITY POLICY Quality should be built into companys products to not only meet customer requirements continuously but also exceed them. The company shall achieve this through an interface with the market place, access to state of the art technology, R&D process development and adoption of innovative manufacturing and marketing strategies. The quality policy shall be implemented through a network of systems and procedures understood and followed throughout the company. The quality policy shall be integrated with the companys main objectives:1. To remain market leader in the quality.2. Increase market share with focus on niche segments.3. Improved productivity.4. Cost reduction.5. Reduction in percentage of seconds. 6. The management shall be committed to provide capital and human resources to achieve the above objectives. A companywide quality culture shall be created through training and motivation of people at all levels of organization.
logo of vardhman
The FLAME signifies the growth of each and every individual associated with it whether he or she is a worker, an employee, shareholder or a customer. The STICK symbolizes cotton, which is basic raw material of the core product of Vardhman Group. The V stands for Vardhman Group.
ADOPTION OF MANAGEMENT PRACTICES
Quality CouncilsA significant step towards total quality management (TQM) is the concept of quality council adopted by the unit, fine quality councils have been constituted to identify the problems and to solve these as projects with efforts of cross functional project teams, consisting of officers from their concern as well as other departments.Cross Functional GroupTo develop better coordination among inter-related departments, 15 functional groups have been formed. These groups meet at specific frequencies to sort out mutual problems and to bring about improvements in systems for better interdepartmental working.Human Resource DevelopmentThe importance of human resources in industry is well established with management and investment for the development of human resources through training and development in continuously being made. This has resulted in building of team of professionals comparable with best in textile industry. Apart from systematic and methodological training of fresh workmen the following developments amounts provided the staff and officers.Officers WorkshopTo keep a breast with new and existing concept in management officers workshop are organized regularly and the officers are nominated and are individually invited to the workshop.The officers so invited exchange their views with help of moderator for about two hours for better clarity and understanding.Workers Development ProgramIndustry started various program for workers so that their mental level can be improved, for the many schemes are launched by the Company, same this Manav Vikas Kendar is organized for the worker to motivate them their problem can be listen and immediately action can be taken against it.
TOTAL PRODUCTIVE MAINTENANCE (TPM)It aims to create a corporate system that maximizes the efficiency of the production system.TPM is based on Participation of all members, ranging from the top management to front line employees.
TPM Policy of Vardhman GroupMaximize overall effectiveness and reliability of the plant and machinery by aiming ata) Zero Break down, b) Zero Defects,c) Zero AccidentThis is achieved through nurturing team work and continuous development of all employees.
MANUFACTURING AND DISTRIBUTION NETWORK
Organizational Hierarchy Chart
CORPORATE SOCIAL RESPONSIBILITY
Sri Aurobindo Socio-Economic and Management Research InstituteSri Aurobindo Socio-Economic and Management Research Institute are engaged in the promotion of education, research and publications highlighting social and economic issues facing the society. The Institute runs a Human Resource Development Centre for providing career counselling and guidance to college students in Punjab. The teams of experts also visit the colleges in the state to prepare college students for gainful employment in the industry.Sri Aurobindo College of Commerce and ManagementSprung from a keen desire to set up an educational institution in Ludhiana and inspired by the writings of Sri Aurobindo and the Mother, the Trust has set up a college - Sri Aurobindo College of Commerce and Management (affiliated to the Punjab University) with the mission to create an institution with distinction dedicated to the ideals of creating disciplined career oriented young people ready for going for administrative and management roles in enterprises or to set up their own business as entrepreneurs.The Village Adoption ProgrammeA Vardhman initiative to improve the yield of cotton in Punjab in 2001 when the State had suffered a shock of crop devastation and area under cotton cultivation was dwindling, led to the experiment to adopt villages and see whether concerted efforts in bringing knowledge to farmers could improve the yield of cotton. The experiment was successful as it improved the yield of cotton to 873 kg/hectare in 2005 in adopted villages where the average yield of cotton in the State of Punjab was 587 kg/hectare (world average - 700 kg/hectare). It found mention in the President's broadcast on Technology Day (11/05/04) as a 'technological event which has the potential to penetrate into our everyday lives'. The Village Adoption Programme also found mention in the President's address to the nation on the eve of India's 56th Republic day. The President of India was gracious to bless one of the participating Villages -'Gehri Buttar' (District - Bathinda) by his presence on December 10th 2005.Nimbua Greenfield Punjab LimitedVardhman is actively engaged in the activities of Nimbua Greenfield Punjab Limited (www.ngpl.co.in) formed by a consortium of Industries of Punjab for developing a common facility for storage, treatment and disposal of hazardous wastes generated by the Industry with a Government of India grant. www.ngpl.co.in)AURO SPINNING MILLS (84000 SPINDLES)PRODUCTION DETAILSNumber of production halls 5UNIT 1 (HALL1)Manufacturing Activity: Greige Cotton (both carded & combed) and core spun with Lycra.Unit Capacity: 24,422 spindles Production of yarn per day: 16,000 kgProduct Range: 10s-60sUNIT 2 (HALL 2)Manufacturing Activity: Sliver preparatory and sample lineUnit Capacity: 1382 spindles Production of sliver per day: 9,000 kgProduct Range: Lycra, compact, compact+lycra, slub+lycra, slub, BlendsUNIT 3 (HALL 3)Manufacturing Activity: Cotton and lycra (bulk orders)Unit Capacity: 38592 spindlesProduct Range: Lycra, slub, fancy yarnsUNIT 4 (HALL 4)Manufacturing Activity: Open- end yarnUnit Capacity: 1248 rotors Production of yarn per day: 12,000 kgProduct Range: 6s-20sUNIT 5 (HALL 5)Manufacturing Activity: Compact (Elite) spun yarnUnit Capacity: 14256 spindles Production of yarn per day: 4000 kgProduct Range: 40s-200s
RAW MATERIAL: INPUTCotton Fibre bales are issued as directed by the planning department Domestic sources J-34 ,S-6 from Maharashtra, Mech -1 from Tamil Nadu Imported sources PIMA & GIZA from Egypt, FOUNDLANDS from USA Bale Weight = 165 kg Count :< 40s count: Indian (go for imported cotton if Indian is too costly)40s - 50s count: blend of imported & Indian used50s: imported cotton used
BLOW ROOMBlow room consists of a number of machines used in succession to open and clean the cotton fibre. About 40% -70% trash is removed in blow room section.PROCESS FLOW IN BLOWROOM
Pre-opening with blendomat BDT