Operation Management Report by M.tauqeer

8/9/2019 Operation Management Report by M.tauqeer

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Table of Contents

ACKNOWLEDGEMENT ------------------------------------ 03

COMPANY PROFILE ----------------------------------------- 05

SPINNING ------------------------------------------------------- 11

WEAVILNG------------------------------------------------------ 14

PRETREATMENT--------------------------------------------- 18

DYEING (Export) ----------------------------------------------- 20

DYEING (Local) ----------------------------------------------- 25

COLLAR KITCHEN ------------------------------------------- 27DESIGN ENGRAVING -------------------------------------- 29

PRINTING --------------------------------------------------------32

FINISHING -------------------------------------------------------36

FINISH EXPORT FOLDING ------------------------------- 39

THE LABORATORY ----------------------------------------- 42

QUALITY ASSURANCE ------------------------------------ 45

WAREHOUSE ------------------------------------------------- 47

CONFECTION -------------------------------------------------- 49

SALES CONTRACT ----------------------------------------- 54

SAMPLING ------------------------------------------------------ 57

CUTTING LETTER --------------------------------------------58PROCUREMENTS ------------------------------------------- 60

INTRODUCTION TO MERCHANDIZING -------------- 62

SUGGESTIONS ----------------------------------------------- 65


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ACKNOWLEDGEMENT

Assuming of any role in a new organization is a source of great anxiety. An orientation programdefinitely helps eliminate this anxiety and removes a number of ambiguities. I felt myselfextremely fortunate for having found the opportunity to go through a very comprehensive

orientation program.

Gul Ahmed Textile is a great organization involved in composite operations. Not only theoperations are very large in terms of volume but also are highly technical. It is almost

impossible to get insight of the entire organization in a limited time. However, the orientationprogram has been extremely useful in developing the basic knowledge about the organizationand the functions of its units reasonably in good number (by the Grace of Allah Almighty).

I am thankful to the Operation Manager Mr. Fazal-Ur-Rehman & General Manager Mr. DanishAdam jee, whose help and assistance enabled me to successfully complete this report. I am alsovery thankful to Mr. Hadi Fayyazi , Mr. Saeed Akhtar , Mr. Majid Khan and others to give metheir precious time in completing my assignment, and passing their great experience.

Again a humble vote of gratitude to all the respected employees, for designing such a pattern for

us and guiding us on the right path.


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GUL AHMED TEXTILE

MILLS

COMPANY PROFILE & HISTORY


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HT/4B Landhi Industrial Area Karachi 75120Pakistan

Telephone 92-21-5082626-30

Fax 92-21-5082625

Email [email protected]

Operations

1. Spinning.2. Weaving.3. Design & Styling.4. Pretreatment, Printing, Dyeing, Finishing.5. Hemming of house hold textiles.

6. Quality Control.

Group of Companies

Following is the list of companies, which are part of the group.

Gul Abmed Textile Mills Limited

Swisstex Chemicals

Gul Abmed Energy Limited

Business Activities

Textiles

In the textile field, activities start from spinning of raw cotton and man made fibers, and theseare spun into yarns. These yarns are then woven into a variety of fabrics, which are processedand finished in all types of cotton and blended fabrics, bed linen and home textiles includingcurtains.

Apparel

Gul Ahmeds Apparel Division has established a tremendous presence in the International markets especially in United Statesand Europe, since its establishment in Year 2006. We supply to major clothing brands and large buying houses. Our sewing

manufacturing facility has an in-house production capacity of 5.4 million units per annum and is 100 % export based.

We produce the highest quality garments and our entire organization and production processesare equipped and continuously updated to satisfy our buyers. Our reputation and commitmentwith our valued customers is our highest asset

Power

The group is pioneers in the field of power generation. The textile mills are on self-generationwith an installed capacity of more than 20 MW.

Management


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Management of the group is professionally qualified and broadly experienced. The company'sdirector has held top position in various textile bodies, exports committees and assisted thegovernment of Pakistan in trade talks & negotiation with EC & USA authorities in framingtextile policies.

Mission Statement:

To produce quality products through emphasis on consumer needs and toearn profits through total consumer satisfaction.

Vision Statement:

To be the textile leader of value added products in Pakistan and to achieve a

turnover of 300 million US $ in the next 15 years.

Product:

Gul Ahmed's fine textile products represent a unique fusion of the century oldtraditions of the east and the latest textile technology of the west. The purest of cotton fibers,

produced from the fertile lands of the Indus Valley, are spun, woven and processed into thefinest quality cotton and blended products through a combination of latest technology, skillsand craftsmanship of this traditional industry.

1)Bed-LinenQuilt covers ,duvet covers, flat and fitted sheets, pillow covers, valance sheets, bolster case withall sorts of fancy confectioning, embroidery and embellishments, packed to buyers' specificrequirement.

2)Curtain

Ready made curtains lined, un-lined and taptop curtains, plain or fully accessorized with

tiebacks, pelmets, cushion covers, in different styles of confectioning and embroidery, packed tobuyers' specific requirement.


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3)FabricRunning meter fabrics, packed to specific requirement.

4)YarnGul Ahmed specializes in medium-to-fine-count cotton yarns and is also capable of producingyarns using a wide variety of synthetic fibers including polyester, rayon and other man-madefibers

5)OthersAll APPAREL Articles , Boxer shorts, carpenter shorts, Mens , Boys , Womens Tee Shirts,

Hooded, Trouser, Apparel Items, cycle shorts, table linen, kitchen linen, sofa cover, quiltedarticles including bed spreads, comforters, etc.


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SSPINNINGPINNING

he Orientation Program started from the Spinning Department. Gul Ahmed has its ownspinning facility located in Landhi Mill no 5. The contact person was Mr. Mehmood

Director Technical Production. However the orientation was conducted in two sessions. Thespinning facility at GTM 5 comprises of two significant divisions the Production facility and theTesting Lab.

T

Production Facility.

The production facility comprises of several departments. Mr. Ashraf provided a detaileddescription of each department and gave description of each and every work process. First thecotton bales are received at the warehouse. This cotton is purchased based on the sample selected


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and onwards approval from the lab. Cotton Bales are mostly purchased from Sind, Punjab, and insome cases even from abroad. The most frequently purchased cotton is MNH 93 produced inPunjab.

Plucking.

At this stage cotton bales are manually opened and are put in Pluckers. Pluckers are machineswhich mix the cotton and separate the bales into smaller denominations. The separated cotton isthen transferred into the Blow Room.

Blow Room

The Blow Room is a facility, which is primarily used for the Cleaning, Mixing and Opening ofcotton for yarn production. Cotton is processed through various stages in this area throughdifferent machines and the main objective is to refine the cotton being used in yarn production. A

brief description of the machinery used is given below.

Auto Blender Primarily used for mixing cotton. This means that the cotton fibers are separated for thefacilitation of the cleaning process. Waste at this stage is also removed.

B-11 This machines is mainly used for trash removal. The cotton is passed through channel with air pressure.Trash is removed and deposited at the bottom of the machine while the cotton is passedon for further processing.

Multimixer Again multimixer is another machine used for further mixing and opening of the rawcotton.

Heavy Particle As this is self explanatory this machine is used to remove trash and

Separator facilitates in the cleaning process.

Tower Feed Free This is mainly used for beating cotton so that the fibers are furtherRoller aligned.Tower Feed Free This is mainly used for the further waste removal and fine opening ofFine Opener cotton fiber.

Tower Feed Free The tower has wires attached to its beater which further separates theWire Opener fibers.

Vision Shield The vision shield is yet another equipment to purify the raw cotton. This device containssensors which sense the foreign particles (Trash) i.e. polythene, leafs etc. and sucks them

out of the raw cotton through air pressure.

D Duster This is the final stage in the blow room in which even the tiny and micro dust particlesare removed from the raw cotton. Once the cotton is passed through the D Duster it istransferred into the Carding department.

The Carding Department.

The main function of this department is to transform the cotton into Sliver. The main objectivehere is to maintain the uniformity, alignment and stretch ability of the fiber as per the desiredstandards. Once the Cotton is turned into Sliver it is filled in Cans. Cotton is passed throughDrying Breaker to maintain the uniformity; the fiber is straightened. The sliver is then passed to

Drying Finisher is for the same purposes however the only difference is that of the Auto Leveler.The Auto leveler is primarily used for controlling the variasion in uniformity (weight) of thesliver. The unit of measure for uniformity is Grain.


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Simplex.

Simplex is the process of shaping the Sliver into Roving. The main processes involved areGrafting, Twisting and Winding the sliver and shaping it like a thin rope. There are currently sixmachines used for turning the Sliver into Roving. Each machine has a capacity of 120 spindles.Spindles are the equipment on which the Roving is collected. The unit of measure of roving is

Hanks. Once the roving are collected it is passed on to the Ring Department for yarn production.


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The Ring Department.

This is function where the yarn is finally produced. The Rovings are put on the machines usedhere and passing the roving through the machine produces yarns. The main objective of themachines here is again Grafting, Twisting and Winding. Once the cotton thread is produced it is

collected in the from of Bobbin.

The Auto Cone Department.

The main equipment used in the auto cone department is a machine called Loepee. The functionof this machine is to observe the yarn and remove the unwanted portion of the yarn. If a portionof the threat is identified as unwanted it is removed and the threat is then again joined tocontinue with the process. All sensed thread is collected on a Cone. The cone is of a Standardsize. Once a cones are completed they are transferred to the packing department from where theyare packed and stored.

Spinning Laboratory

The second important section of the spinning facility is the Test Laboratory which is mainlyresponsible for the inspection and testing of the cotton samples and monitoring the work

processes and machinery in the production facility. Mr. Saleem provided a detailed descriptionon the work processes of the Lab.

The Yarn Section.

The first section in the lab is the Yarn Department in which the production is monitored

according to the set and desired standards. There are various machines and equipments used forthis purpose which the performance and output of the production facility.

The Wrapping Drum: This is an equipment used to measure the count i.e. Grains of the Sliver being produced.67 grains is the standard unit to measure the thickness.

The sliver is rolled on the wrapping drum and six rounds of the wrapping drum are taken. Once six roundsare completed the sliver is cut and weighed. The grains of the sliver are then computed bythe application of a formula.

The Strength Machine: The strength machine is used to measure the strength of the yarn. 120 yards of yarn arerequired to measure the strength of yarn. 120 yards of yarn equals to one Lie. A 30-count yarn has strength of 72 pounds. There are other standards to measure other countsas well.

Auto Sorter: Auto sorter is device, which inspects the count of both the Yarn and the Hanks.

UT4: This devise is used to run similar detailed tests, which inspects the Sliver and the Yarn.

Spectro Gram: This device detects the technical fault in the machinery operational in the mill.

WWEAVINGEAVING


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(Procedure)

eaving is method or process of interlacing two yarns of similar materials so that theycross each other at right angles to produce woven fabric. The warp yarns, or ends, run

lengthwise in the fabric, and the filling threads (weft), or picks, run from side to side. Weaving

can be done on a power or handloom or by several hand methods. At Gul Ahmed TextileWeaving is done on both Air Jet Looms and Sulzer Looms. There are separate facilities forweaving for both markets i.e. Local as well as Exports.

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In case of Weaving for Exports the facility has been established in GTM 5 and for Local facilityhas been setup at GTM 4. The process is initiated from the Yarn Warehouse. Yarn is separated inthe Yarn warehouse where the Yarn to be utilized in the Warp and the Weft are segregated.

WARP: Its the set of yarn in all woven fabrics, that runs lengthwise (veridical ) and parallel

to the selvage and is interwoven with the weft.

WEFT: In a woven fabric, the yarn running from selvage to selvage (Horizontal) at rightangles to the warp threads .Each Vertical thread is called a pick or Weft.

BEAMING (Warping): The operation of winding warp yarns onto a beam usually inpreparation for slashing, weaving, or warp knitting. Also called warping. Once the Warp endsare separated they are brought to a machine where these warps threads are aligned on the beamfor the purpose of weaving. The size of the beam may vary and infact the width of the fabric isdependent of the width of the beam. Beam sizes and number of ends per beam. Currently at theExport Weaving facility the Warping Machines have a capacity of Warping 704, 800 and 1040threads on once beam. Where is

SIZING: A generic term for compounds that are applied to warp yarn to bind the fibertogether and stiffen the yarn to provide abrasion resistance during weaving. Starch, gelatin, oil,wax, and manufactured polymers such as polyvinyl alcohol, polystyrene, polyacrylic acid, and

polyacetates are employed. Beams containing the Warp ends are then put on the sizing machinewhere the warp ends are passed through chemical compounds so that strength of the yarn isincreased. Several Beams can be loaded on the Sizing machine at a time. Currently the sizingmachines at the export facility have two capacities i.e of 24 and 28 beams. Depending upon thequality of weave required. New beams are created out of the beams loaded on the Sizingmachine. Example if its a quality of 76 x 68 with a width of 100 then the number of warp endsrequired on one beam shall be 76 x 100 i.e. 7600. However the Warping machine can only Warp

1040 threads on a beam at a time. Thus to get 7600 threads 8 beams shall have to be made. Allthese 8 beams are then put on the sizing machine and then the Warps ends of all the eight beamare passed through the chemical at the same time and collected on one beams.


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WASTE RECYCLING: Waste is recycled at both the Warping as well as the Sizingstage. All waste which is acculate is then send to the rewinding.

DRAWING: Drawing is a very important and time consuming process in the weaving of the

fabric. It is infact a process in which the texture of the fabric is shaped. Setting the pattern ofintersection of the Warp shapes the texture of the fabric and Weft ends. However the patterns isset up by the dropper, dropper rod and the frame which shall be important in shaping the textureof the cloth. Once the Drawing of the Beam is completed the beam is ready for being passed onto the loom shed.

LOOM: The Loom is the actual machine for weaving fabric by interlacing a series ofvertical, parallel threads (the warp) with a series of horizontal, parallel threads (the filling). TheYarn separates in the beginning for the Weft is directly brought to the loom shed. The warpyarns from a beam pass through the heddles and reed, and the filling is shot through the shed

of warp threads by means of a shuttle or other device and is settled in place by the reed and lay.The woven fabric is then wound on a cloth beam. The primary distinction between differenttypes of looms is the manner of filling insertion. Mainly there are two types of looms being usedin Gul Ahmed i.e. the Air Jet Loom and the Sulzer Loom however Air Jet is only used for the

purposes of Export Weaving.

KNOTTING: Knotting is a process in weaving when the beam is replaced by a fresh newbeam. This is done when an existing quality of the fabric is being produced on a loom and theWarp thread on the beams are about to be fully consumed the Machine is stopped and theexisting beam is replaced by a new beam however the Warp ends are knotted together with the

ends of the previous beam so that the production is continuous.

GETTING: When once particular quality is manufactured and is completed the complete setof the beam, rod, and dropper etc is removed and a new set is loaded for a different quality. This

process is called the Getting.

INSPECTION AND FOLDING: Once the fabric is weaved it is rolled in 150 to 200meter length rolls. The fabric is then inspected and folded. The Main purposes of the inspectionis to check the weaving defects that arise during the weaving process. The fabric once inspectedis folded and passed on to the packing department for packing. Once packed the fabric is kept in

the fabric godown.

The Unit of Measures.

The Count:

The Count is mainly the twist of the yarn. 1 pound of Yarn containing 840 yards of thread isequal to 1 single count. The a count of 80 is 80 x 840 yards of thread in one pound ofyarn....................................................................................................................................................

.(if you need complete report pls contect me tauqeerrajput@gmail or

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Operation Management Report by M.tauqeer