81
ALLEPPY CO-OPERATIVE SPINNING MILL CHAPTER- 1 INTRODUCTION 1 ORGANIZATIONAL STUDY

Sarath

Embed Size (px)

Citation preview

Page 1: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

CHAPTER- 1

INTRODUCTION

1 ORGANIZATIONAL STUDY

Page 2: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

1 .1 Introduction to Study

As per the MBA curriculum organization study is the necessary one. It provides

an opportunity to apply knowledge and skill in the real world. Organizational structure refers

to the formal established pattern of relationships amongst the various Parts of a firm or any

organization.

In this study at the alleppy co-operative spinning mill, is an attempt made to study

and to understand about the basic element of an organization including the functional and

managerial aspects. This study throws light in to the textile industry in general, structure and

the functioning of different departments in the spinning mill.

This study helped to me to understand about the production prevailing in the textile

sectors and the constraints which are being faced by the millions now present in Kerala. The

important of textile industry is the single most exporter earner (around30%) of the gross

exports earning for India and it is the second most employment provider after agriculture

sector. Thus the study will enable a more tangible and efficient way.

1.2 Objectives of the study

1) To make theoretical belief in to practical knowledge

2) To get in touch in and communicate with all the people or worker from top to

bottom of the organization.

3) To understand about the origin, history and future plans of the company.

4) To understand about the product & services provided by the company.

5) To know the functioning of various departments.

6) To understand SWOT of the organization &there by providing suggestions for the

company to improve its efficiency.

2 ORGANIZATIONAL STUDY

Page 3: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

1.3 Significance of the study

As a management student this organizational study helps to understand various

functional and managerial aspects of the firm. It gives theoretical as well as of the firm and

knowledge regarding the management of the firm.

This industrial exposure has enables to understand the practical use of these various aspects.

The organizational study about various functional & managerial aspects of the organization.

1.4 Scope

The report related with the study of organizational structure and over the following aspects

a) History of the company

b) Relation between the management and the workers

c) The planned polices, the procedures, controls that guide activities & relationships

communication networks etc.

d) Position and performance of the company.

This organizational study provides an insight in to the fascinating world of management

study. It helps to incorporate the theoretical knowledge with practical knowledge and also

this is a sleeping stone for the final project.

3 ORGANIZATIONAL STUDY

Page 4: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

1.5 Research Methodology

Methodology is a procedure or technique in research study or investigation. There are

mainly two sources of data collected they are:

A) PRIMARY SOURCE

In this type data collected mainly through direct observation, formal interview with

Managers, department `heads, interaction with different levels of employees. There are also

called first hand information.

Primary data are also collected through the following methods

1) Experimental method

2) Survey method

The above methods including following techniques for the collection of data

1) Direct observation.

2) Unstructured interviews.

3) Listening to the general talks by the department heads.

B) SECONDARY SOURCES

Secondary data can be defined as data collected by someone else for the purpose other

than solving problem. The data in published & unpublished sources depends on these

secondary data.

They are two types

1) Internal sources

2) External sources

The secondary data can be obtained from

Technical and trade journals

Books, magazines &newspapers

Journals published by him

Annual report of the company

Operating manuals of various departments

Company website, Unpublished sources are also available

4 ORGANIZATIONAL STUDY

Page 5: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

1.6 Limitations of the study

Time constraint was limiting factor.

ACSM were dealing all the market with agents no direct marketing So it is difficult to

find out the making situations

Finding customer attitude about the product is a difficult task.

The study was conducted in a single organization; hence comparison with not possible.

5 ORGANIZATIONAL STUDY

Page 6: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

CHAPTER-2

INDUSTRY PROFILES

6 ORGANIZATIONAL STUDY

Page 7: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

INDUSTRY PROFILE

Textile is derived from Latin word ’TEXERE’which means to weave. It was originally

applied only to woven fabrics, but now a general term for fibers yarn and other materials. The

major cotton producing states are Punjab, Haryana, Gujarat, Maharashtra, Rajasthan and Andra

Pradesh. India has the largest hector age in the world amounting to a million hectors or 25% of

the textile industry in Kerala is rather small compared to the best of the country. In Kerala in

order to satisfy the raw materials needs of waves, government of Kerala stated 5 spinning mill

under co-operative sector.

The public sector units in textile sector where mainly engaged in the activities of yarn

manufacturing. The 9 units including the 4 companies owned by employee around 5979

personnel accounts for 10% of total employment in enterprise under industries development. The

major problems of textile one is

1 Cotton export and price.

2 Delay in cotton yarn exports.

3 Non-availability of credit.

4 Low productivity.

5 Change of fashion.

6 Power problems.

PROCESS

In spinning process, separate fibers are trusted together to bind them in to a stronger long yarn

vary based on the material used, fibers length and alignment, quantity fibers used and degree of

twist. The direction in which the yarn is spin is called twist and yarn are characterized on 2 twists

or 5 twists according to the direction of spinning rightness of twist is measured in twist per inch

7 ORGANIZATIONAL STUDY

Page 8: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

(IPI). Two or more spun yarn may be twisted together or piled to form a thicken yarn. Generally

hands Spun single piles one spun with a Z-twisted and playing is done with an S-twist.

CONTEMPORARY HAND SPINNING

With the recent part, many new spinners have joined into this ancient process

innovating the craft and creating new technologies from using many new applicants of dying

before wouldn’t be in a traditional yarn, to crafting techniques like coiling, this craft is

constantly evolving and shifting.

A woollen yarn is contrast hand spun from a role where the fibers aren’t as strictly aligned to

the yarn created. The woollen yarn captures much more air and makes for a soften to

convene and generally bulkier yarn. A spinner will spin using varying techniques for

handcrafted and roles based yarn and thus make a semi-worsted yarn. Woollen can be dyed at

any time, but is often dyed before carding due.

HISTORY OF TEXTILE IN INDIA

Cotton mill first attempt by bowery cotton mills near Kolkata by English enterprises

1st mill as established by C.N. DAVER in1854, Mumbai. Textile is the second largest

industry in India after agriculture industry.

TEXTILE INDUSTRY IN NATIONAL SCENARIO

The industrial growth of the country was piloted by textile industry even before

independence and occupied a very unique position by its contribution to the national product,

export and final consumption expenditure. Cotton played a dominant role in the growth of

the industry in the country. The major cotton producing states are Punjab, Haryana, Gujarat,

Maharashtra, Rajasthan, and Andhra Pradesh. Through India has the largest cotton hector age

in the world around 9million hectors, the production in the country is hardly 20% of the

world production. The textile sector is major contribution to the foreign exchange earning of

the country for 35% of the total export. There are 1767 textile mill in the country of which

192 are in public sector, 151 in co-operative sector and 1424 in private sector.

8 ORGANIZATIONAL STUDY

Page 9: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

THE KERALA SCENARIO

The size of the textile industry in Kerala is rather small compared to the rest of the

country. It comprises 30 textile mills. The textile industry in Kerala comprises of handloom,

power loom and mill sector. Handloom is one of the major traditional industries in the state.

40 Power loom in co-operative sector and 170 in private sector together it’s constitutes. 10%

of the total employment in the industrial sector. Total spindlege as follows, Central sector-

130208, State sector-109174.

MAJOR PROBLEMS IN INDUSTRY.

1. Cotton export and prices.

2. Decline in cotton yarn export.

3. Lack of modernization.

4. Non availability of credit.

5. Increase in cost of production.

6. Low productivity.

7. Power problem.

GENERAL CONDITION OF TEXTILE MILL.

The public sector units in textile sector where mainly engaged in the activities of yarn

manufacturing. The 9 units including the four companies owned by employee around 5979

personnel and accounts for 10% of total employment in enterprise in under industries

department.

9 ORGANIZATIONAL STUDY

Page 10: Sarath

Raw material

Bale Board

Mill

Spinning mills Composite Mills

Yarn

Knitting

Knitted Cloth

Market

Consumers

ALLEPPY CO-OPERATIVE SPINNING MILL

Process flow chart of textile industry.

10 ORGANIZATIONAL STUDY

Handloom Power loom

Page 11: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

HISTORY OF COTTON

Prior to the manufacturing process being mechanized textile where produced in

the home and excess sold for extra money. Most cloth was made from wool. Cotton or flax,

depending on the era and location.

During the late medieval period, cotton become known as an imported fiber in

northern Europe, without any knowledge of what is come from other than that was a plan.

Nothing it’s similarities to wool, people in the region could only imagine that cotton must be

produced by plant born sheep.

John Mandeville, writing in 1350, started as fact that the now preposterous belief.

“There grew there (India) a wonderful tree which hooraying lambs on the ends of its

branches. These branches were so pliable that they bent down to allow the lambs to feed

when they are hungry”.

“Tree wool” by the end of 16th century, cotton was cultivated throughout the

warmer regions in Asia and America. In Roman Times, wool and leather clothed the

European populations, the cotton of India was curiosity that only naturalized had heard of,

and silk, imported along the Silk Road from china, was an extra-vagant luxury. The use of

flax in the manufacturing of cloth in northern Europe dates back to Neolithic Times. Cloth

was produced in the home and the excess woolen cloth was sold to merchant called clothiers

who visited the village with their trains of pack horses. Some of the cloth was made into

clothes for people living in same area and a large amount of cloth was exported.

The process of machining cloth depends slights on the fiber being used, but there

are three main steps: Preparation of fibers for spinning and weaving or knitting. The

preparation of the fiber differs the most depending on the fibers used flex requires ratings and

dressing, while wool requires carding and washing. The spinning and weaving process are

very similar between fibers through spinning is the process of creating yarn or thread, rope,

cable from various rope fiber material, yarn can be made from a wide variety of materials.

11 ORGANIZATIONAL STUDY

Page 12: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

They are;

Plant fibers-Cotton, flax, bamboo, coconut husk, soy.

Animal fibers-Wool, goat, rabbit, dog, camel, yack and silk.

Artificial fibers-Nylon, rayon, polyester, tinsel.

Spinning involved from twisting the fibers by hand, to use of a

drop spindle to a spinning wheel spindles or parts of them have been found in very old

archaeological sites they may present one of the earliest pieces of technology available to

humankind was invented in India between 500 and 100 AD. It reached Europe via the Middle

East in the European middle ages.

12 ORGANIZATIONAL STUDY

Page 13: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

CHAPTER -3

COMPANY PROFILE

13 ORGANIZATIONAL STUDY

Page 14: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

COMPANY PROFILE

The textile industry is divided in to four sectors .They are National Textile

Corporation (NTC), Kerala State Textile Corporation (KSTC), Kerala State co-

operative Textile Federation Limited (TEXFED) and private sector.

TEXFED was established during 1992 with the objective to plan, advice, &co-

ordinate, assist, monitor, supervise, setup manage and to facilitate the working of the

organization. ACSM is under TEXFED. Spinning mills under the membership of

(TEXFORD) are;

a. Malabar co-operative textiles kuttipuram

b. Priyadharshini Co-operative Spinning Mills, Meenadom, Kottayam.

c. Mala Co-operative Spinning Mill ,Trissur

d. Kannannore Co-operative Spinning Mills ,Kannur

e. Malappuram Co-operative Spinning mills,Mallappuram

f. Trissur CO-operative Spinning Mills ,Vazhani,Trissur

g. Quilon CO- operative Spinning Mills ,Chathannur ,Quilon

h. Alleppy Co-operative Spinning Mill ,Kayamkulam

Alleppy Cooperative Spinning Mill registered on 21-07-1981 by number DI/7934/81

was commissioned on 30-10-1999 with a capacity of 6000 spindles. The Govt. acquired

7.9 hectors i.e., 19.5 acres of land in pathiyoor village, Kareelakulangara, Kayamkulam in

Alleppy District with an estimated value of 26.9 lakhs.

This Mill was set up by the All India Federation OF Cooperative spinning Mills Ltd,

Mumbai. The total estimated cost requirement for the mill was 1136.00 lakhs as per the

SITRA standard. The initial membership of the society was 34 members and registered

under Kerala Cooperative sector and registered under Kerala Co-operative Societies Act

1969.

14 ORGANIZATIONAL STUDY

Page 15: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

When the Alleppy Co-operative Spinning Mill started functioning there

were seven spinning machines. The capacity of the machines is 864 spindles

which make up a total of 6048 spindle. The company had a debt of about six core

in the Alappuzha district Co-operative bank, in order to clear this debt the

company had sold its 10 acres of land . The money they got after clearing the

debt was used for expansion purpose. From 15 Dec 2010 ACSM has 13 spinning

machines which make up a total of 12000 spindles. The master plan of this firm is

to increase the number spindles to25000 and ACMS started. With the help of

Kerala grand ACMS started a project called hank yarn project for hand loom. The

Kerala State Industrial Reconstruction and Internal Audit Board (RIAB) have

selected ACSM as model in 2010.

Objectives of the company

The object of the Mills is to carry on the business of cotton &staple fiber spinning.

For the purpose of attaining the aforesaid object it shall be completed for the Mill.

1. To purchase, take on lease or acquire any property & to construct

erect, maintain or other woks necessary for the purpose of Mills.

2. To purchase or acquire and deal in cotton &other raw materials

The production process of Yarn yields wide verities of wastes which can be used for

Noil used as yarn by allowing it to re processing process

Hard waste used for workshops

Flat strips used for surgical cotton

Peneumafiles can be used again by allowing in reprocessing process

15 ORGANIZATIONAL STUDY

Page 16: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

DEPARTMENT OPERATIVE EMPLOYEE

1) Electrical

2) Watch & word

3) Attender, office boy, peon mill

4) Store keeper mill

5) Canteen

1) Per 1000 spindle per shift

2) Per 1000 employees

3) Depends on the size of the

4) Depends on the size of the

5) Depends on the size of the

VISSION & MISSION

Vision is to produce the highest quality of fine and super fine yarn in the world. And also provide the

beast customer service in the industry.

Vision towards public: Ginning of cotton gives cattle field to the market, spinning of yarn from

cotton is exported to domestic markets.

Vision towards quality: It is the policy to provide quality cotton yarn in a competitive rate to

ensure customer satisfaction

Vision towards employees: Provision of continuous employment and welfare to the employees

attached with ACSM.

ACSM is continued to operate a successful business by developing, manufacturing, marketing, and

supporting quality yarn products for the world textile industry. It can be achieved by;

Developing long- term relationship with customers and suppliers.

Providing superior quality products at competitive prices.

Exceeding industry standards with exceptional customer and technical service.

Maintaining competitive position through leading edge technology.

Providing a safe, fulfilling and recording work environment for the employees

Serving supporting the communities which they operate.

16 ORGANIZATIONAL STUDY

Page 17: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

The company works on all days in the week except on Sundays. The Company works for 24 hours in

shifts and a general shift. The time of the three shifts and general shifts will be as follows:

WORK SHIFT TIME

General Shift 9:00 AM- 5:00 PM

First 7:00 AM – 3:00 PM

Second 3:00 PM - 11:00 PM

Third 11:00 PM – 7:00 AM

Out of 12 days of casual leave women are allowed to take leave for two days in a week. And in case of

men they are allowed to take only one

Day leave in a week. Both of them are given separate rest rooms and

Canteen facilities provided in the mill itself with a cheap rate. Other

Benefits provided by the company are provident fund, ESI and night

allowances.

Co-operative governance

The board of directors periodically reviews the company’s strategic decision. Business plans and

targets are set by the Chief executive and reviewed by the board. The board is committed to

Maintain a high standard of co operative governance. The board has reviewed the code of co operative

governance and confirms that: -

* Financial statements, prepared by the management of the company present fairly state of affairs, the

result of its operations, cash flows, and changes in equity.

* The company can maintained books of accounts

* Appropriate accounting policies have been consistently applied in preparation of financial statements

and accounting estimates are based on reasonable and prudent judgment

* The system of internal control, which was in place, is being continuously

reviewed by the internal audit and other such procedures

17 ORGANIZATIONAL STUDY

Page 18: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

* All the liabilities in regard to payment on account of taxes,duties,levies and charges have been fully

provided and will be pair in due course of where claim was not acknowledged as debt the same is

disclosed as Contingent liabilities in the note to the accounts.

* The board in complaints to the code of co- operate governance has Established an audit committee

and the following directors are its Members

# General Manager

# Finance Manager

# HR Manager

* The company operates an un -funded gratuity scheme for its employees’ and provision has been made

in the accounts accordingly

18 ORGANIZATIONAL STUDY

Page 19: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

CHAPTER -4

PRODUCT PROFILE

19 ORGANIZATIONAL STUDY

Page 20: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

PRODUCT PROFILE

Raw materials being used are cotton taken from the flower and processed to convert it in

to Yarn. Raw materials are purchased from Andra Pradesh, Tamilnadu, and, Maharashtra. The

quality of raw materials and those of Yarn is based up on SITRA standard .The mill follows

centralized purchase strategy. The raw materials are collected in the form of bale.

The Yarn produced in ACSM is marketed through Dippo marketing with the help of

agents in Mumbai. They are Ramaninkal Nndalal brothers and Sathyam Enterprise, other than

this group The Kerala state Handloom Development Co-operation (HANDWEAVE), National

Handloom co-operation ,Kerala state weavers co-operative society(HANTEX)buys the yarn at

subsidy rate and distributes it to the customers. The mill also do direct sale to affirm called

salvias.

In ACSM the functional norms and rules are expressed/ stated by the south Indian Textile

Department Research Association, Coimbatore being followed in the mill.

In ACSM yarn is produced from the cotton which is extracted from the flowers of cotton

which are purchased from various parts of our nation. A single fibred of cotton should have the

length of minimum 30mm.other short length cotton fibers are waste which are selling to other

mills on quotation basis (6 months or 1 year) for manufacture less quality yarn .This provides

mainly types of Yarn. They are.

4.1 CARDED YARN

Carding removes tangles in fibers but does not fully align the fibers so they are all the

going in exactly the same direction. Most may be going in one direction but there will always be

some going off in their own direction.

More compact , smoother yarn can produced if the fiber is spun with most of its fibers going in

one direction of spinning.(i.e., toward the spinning wheel).If it is spun with most of its fibers

20 ORGANIZATIONAL STUDY

Page 21: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

perpendicular to the spin , it will produce fluffier ,airier yarn . In ACSM, Carded yarn has the

quality count as 62’s. It has less cleaning &strengthening methods compared to Combed Yarn.

4.2 COMBED YARN

Combing is much more labor intensive. Fine toothed combs are used to straighten and

align each individual fiber is being spun. Combed yarn has the quality count as 60’s, which has

high quality compared with carded yarn. It is more regular and expensive than carded yarn.

When cotton or another fabric is “combed”, the shortest, additional fibers of a batch are

removed. The result produces high-quality, extra soft yarns with excellent strength and softness.

4.3 HANK YARN

In the textile industry, a hank refers to a unit of yarn or twine that is in a coiled form.

This is often the best form for use with hand looms, compared to the cone from needed for power

looms. Hanks come in a fixed length depending on the type of material, so the term is sometimes

used as a measure. For instance, a hank of listen is 270 meters, and a hank of cotton or silk is 768

meters.

The quality is based on some standards laid down by SITRA (South Indian Trade

Research Association) .Both carded and combed yarn is tested these standards. Carded yarn has

the quality count as 62’s and Combed yarn has the quality as 60’s possess the highest demand in

the market. The product of ACSM is marketed through Dippo marketing with the help of agents

in Mumbai.

21 ORGANIZATIONAL STUDY

Page 22: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

CHAPTER -5

ORGANIZATIONAL STRUCTURE

22 ORGANIZATIONAL STUDY

Page 23: Sarath

Chairman

Board of Directors

Administrative Manager

General Manager

Mill Manager

Production Manager

Spinning Master

Assistant Manager

Supervisor

Employees

Marketing Manager

Assistant Manager

Dealer

Agents

Customer

Finance Manager

Accountant

Cashier

Personal Manager

Assistant

Store keeper

ALLEPPY CO-OPERATIVE SPINNING MILL

ORGANIZATION CHART

23 ORGANIZATIONAL STUDY

Page 24: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

CHAPTER -6

DEPARTMENT STUDY

24 ORGANIZATIONAL STUDY

Page 25: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

DEPARTMENT STUDY

Organization is a roof under with group of people join together as a team towards common

objectives. This is achieved when there is an organized effort from all concerned. The organizational

objectives are the desired state of affairs which an attempts to realize.

Realization of objectives is sought through the coordinated efforts of the people and resources

which constitute an organization. Resources include money, machine, materials, and people. Essence of

management is the integration of various organizational departments.

In every organization there are mainly four departments which co-ordinate the work and

maintain a god relation with the superior and subordinate. In ACSM, the functions of management are

divided in to five departments.

1 Personnel Department

2 Production Department

3 Finance Department

4 Marketing Department

5 Quality Control Department

25 ORGANIZATIONAL STUDY

Page 26: Sarath

PERSONNEL MANAGER

ASSISTANT PERSONNELMANAGER

TIME KEEPER

OFFICE ATTENDER

ALLEPPY CO-OPERATIVE SPINNING MILL

6.1 PERSONNEL DEPARTMENT

HR PLANNING ATTENDENCE

HIRING LEGAL

GRIEVANCE CANTEEN

COMPENSATION MEDICAL

APPRAISAL WAGE& SALARY

26 ORGANIZATIONAL STUDY

Page 27: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

Personnel department is the key department of every organization because successful functioning

of an organization is mainly due to the proper behavioral pattern of personnel’s in organization. The

main function of this department is to guide human resource to attain the organizational goal with a high

degree of morale and enthusiasm.

The personnel department of ACSM is mainly concerned with problems regarding the

development of staff and labor force of the organization. The personnel department is concerned

with the procurement, development, compensation, integration and maintenance of the personnel for the

purpose of the accomplishment of the ACSM’s major roles and objectives. The personnel details of the

employees are collected and stored in this department

RECRUITMENT, SELECTION AND PLACEMENT

Recruitment stands for generating a pool of applicants for a job. The success and failure of an

organization depends to a great extent upon this as to how much efficient, experienced and capable

employees are procured and recruited.

Selection is the process of choosing the right candidates for the job and it is essentially a

process of comparing skills, capabilities ,attitudes etc. of prospective employees with that of the

standards stipulated by the job analysis .

Induction is concerned with the problem of introducing or orienting the new employee to the

organization.

In ACSM the workers are selected through advertisement. The vacancies are published in the

papers. Selection based on the level of skill, qualification, intelligence, values etc

TRAINING AND DEVELOPMENT

Training is the systematic program of the organization which aims at increasing the aptitudes,

skills and abilities of the workers to perform specific jobs. It is not the act of increasing the

knowledge skills of an employee for doing a job it is also concerned with the purpose of

introducing an employee towards the rules and norms of the organization.

27 ORGANIZATIONAL STUDY

Page 28: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

In ACSM the training program is given to their personnel to

Make them aware of standards of performance.

To meet the needs of the emerging situations such as damage in any of the machines.

To make further development in their ISO 9000series of standards.

Training programs in alleppy Cooperative spinning mill Ltd, implement this in three levels.

They are.

Plant level operations

middle level operations

Higher level operations

PROMOTION

In ACSM, the scope of both promotion and transfer is low .In case of promotion; it is based on

qualification, seniority and vacancy. It is also based on the rules of the approved promotion polices.

ACSM doesn’t have any independent transfer policy as part of its HR procedures.

In Alleppy Co-operative spinning mill Ltd, the employees are mainly posted as trainees of the

mil for carrying out various productions related activities. After completing certain period they are

promoted to the next grade based upon certain rules and norms for promoting any employee from

the present level to the next level.

The declaration came in to effect from 1Dec 2001 and followed in the mill to promote the newly

appointed as well as previously employed for this follows.

Trainees should have at least 60% attendance in total to the working days, otherwise the

trainees are not allowed to work thereafter.

Paid trainees should be able to do the work load of the permanent worker after six months in

range of 50-75% and must have attendance percentage of 90% of the total working days

then he/she will considered for the next grade.

After second six months of training the paid trainees shall be able to do 75-100% of the

workload of permanent worker and he should have attendance above90% of the total

working days then only he/she will be considered for the next grade.

28 ORGANIZATIONAL STUDY

Page 29: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

After second six months of training the paid trainees shall be able to do 75-100% of the

workload permanent worker and he should have attendance above 90% of the total working

days then only he/she will be considered for higher grades.

After the third level of training the paid trainees would be able to handle three different

machines and he/she must be able to do 75-100%of the workload of permanent worker and

he should have attendance above 90% of the total working days then only he/she will be

considered for higher grades.

After fourth level of training the trainee will be given training to carry on the full workload of

a permanent employee and if he/she is able to do the work Without much strain and he/she

has developed in such a manner that he/she is maintaining his/her attendance above 90%

then they considered to higher grade.

Even through all the above conditions are satisfied, but he/she is not physically fit to carry out

the workload given then they will not be considered for the higher grade.

If there is any reasonable cause for the absence of trainee from the work then he/she will be

allowed to work in the same grade and then he/she will be exposed to same rules and

regulations which regulate the promotion system exist in the mill.

EMPLOYEE STRUCTURE

Employees are categorized in to:-

Employees under staff regulation.

Employees understanding order.

Total number of employees – 250

Permanent employees -92

Workers category- 79(comes under standing order)

Officers -13(comes under staff regulation)

Temporary Employees

29 ORGANIZATIONAL STUDY

Page 30: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

WELFARE MEASURES

Personnel department in ACSM gives importance in providing Welfare measures to their

personnel. Welfare measures include both statutory and non-statutory.

Welfare measures include Provident fund, Gratuity, ESI, Bonus and Dearness Allowances,

Leave with wages, Family Fund, Overtime Allowances and Night Allowances. These are mainly

given in the form statutory and non-statutory measures.

WAGE AND SALSRY STRUCTURE

WAGE

The employees in the production unit are employed basically as trainees The Wages given to

them are administrated.

For newly appointed Rs.75/day

Below 2 Years Rs 110/day

Below 3Years Rs 130/day

Below 4 Years Rs 150/day

SALARY

Salary administration in ACSM is done on a grade basis. Salary structure comprises of basic

pay, DA HRA, Salary for the office staff is according to the scale of pay, i.e., Salary for the

office staff is according to the scale of pay, i.e., Salary for the office staff is according to the

scale of pay, i.e., BASIC+DA=HRA. Industrial DA is 5700 which is paid on a monthly basis.

ACSM follows salary in payment of wages as per long term agreements.

30 ORGANIZATIONAL STUDY

Page 31: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

WAGES D.A HRA LTC STIPEND

TRAINEES NIL NIL NIL NIL YES

PERMANENT

WORKERS

YES YES YES YES NIL

BONUS

All employees who are considered eligible as per the bonus act will get a bonus of 8.33% (min).

EMPLOYEE STATE INSURANCE (ESI)

It is the social welfare act enacted to give worker and his family medical treatment at the

time of illness. 1.75% of worker total salary is deducted towards ESI. The employer contributes

4.75% of worker’s wages towards this scheme. Worker whose salary is less than Rs25/- per day

need not contribute 4.75% . If he contributes for a period of 6 months , he is eligible for benefit

in the corresponding months . Maximum benefits and employee can is ‘91’days. If the worker is

a deserving candidate he will be given 306 days benefit.

PROVIDET FUND

Both the employer and the employee contribute to P.F. at the rate of 12% of their earnings

per month. It includes administration charges ‘linked insurance charges and charges for family

pension.

LABOUR WELFARE FUND

Currently labor welfare fund is not present in ACSM but, initiatives are taken to make it a

reality.

LEAVE

There will be 12 days casual leave for a worker every year.

31 ORGANIZATIONAL STUDY

Page 32: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

ACCIDENT BENEFIT

If the employees are covered under ESI schemes meet with any sort of accident on duty,

he/she will get the claim amount from the ESI contribution made by them and as from the mill.

VOULENTARY RETIREMENT

During voluntary retirement the employees is confined to get a sum of money from the

gratuity and an equivalent amount from the organization.

FESTIVAL ADVANCE

Permanent workers will get certain sum amount based up on the salary which he gets

normally as festival advance . This amount is recovered from the salary after the payment of

advance in equal five installments.

HEALTH AND SAFETY

In every organization for efficient working process requires the sound health of the persons

engaged there in. Unless the workers are physically and mentally healthy they cannot perform

their duties effectively. The environment of the factory where workers are working must be clean

and free from infection, insanitation, and dust fumes artificial humidification, overcrowding and

other conditions injurious to the health of the workers.

In ACSM the safety officer’s functions are carried out mainly by the assistant manager in the

personnel department. The provision regarding these aspects is followed to the best in order to

maintain both mental and heath conditions of the worker in the mil. They are as follows:

CLEALINESS

With respect to this the following measures are taken in to consideration:

Accumulation of the dirt and refuse are removed daily from the floors of the work rooms

and passengers.

The floor of the work room is cleaned in every week using disinfectant.

Machines are cleaned in every week.

32 ORGANIZATIONAL STUDY

Page 33: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

DISPOSAL OF WASTES AND EFFLUENT

Effective arrangements are made in the mill for the treatment of wastes and effluent arising

after the spinning process of cotton as approved under the prescribed rules.

OVER CROWDING

In order to prevent overcrowding the following measures are adopted in the mill every

worker is separated from each other in every section of the production unit with at least 14.2

cubic meters. After considering this aspect in the workers are given instructions about the

maximum number of workers to be accommodated in each section.

LIGHTING

Every part of the mill is provided with sufficient light and also effective measures are taken

to avoid the formation of glare and the formation of shadows which will cause eye strain.

LATRINES AND URINALS

Sufficient facilities are provided to both workers with sufficient lighting and ventilation is

provided in the mill. Adequate number of sweepers is maintained in the mil for cleaning the

latrines urinals daily

DRINKING WATER

In the mill effective arrangement are made for the purpose of drinking such as

Water facilities are provided at convenient place which will be easily accessible to everyone.

CANTEEN

The canteen service rendered by ACSM is run by the company directly to provide quality

service to the employees. The canteen cost of all the employees are deducted from their salary.

Food is provided free of cost the in the night shift. The subsidy system is utilized by 45%

contribution from the employee.

33 ORGANIZATIONAL STUDY

Page 34: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

SEURITY SERVICE

The security service by the ACSM is under contract from omega security services. The

security personnel are hired from a private company. There are two securities during day time

and during night.

TRADE UNION

Trade union is basically an association of workers in and more professions. It is an

association carried on mainly for the purpose of protecting and advancing the members

economic interest in connection with their daily work.

Profit maximization by exploiting labor resulted in the formation of trade unions to make the management aware of their of their responsibilities towards the most important resources of the organization. Thus Trade unions are formed to protect the interest of the employees.

Trade union is basically an association of workers in one/more professions. It is an association carried on mainly for the purpose of protecting and advancing the members economic interest in connection with their daily work.

In ACSM there are mainly two main groups of trade unions.

Indian National Trade Union congress (INTUC) Centre of Indian Trade unions(CITU)

PUNCHING SYSTEM

In ACSM the regular attendance of the staff and the workers is done through punching

machine. There are three shifts for the workers.

First shift – 7:00 AM to 3:00 PM

Second shift- 3:00 PM to 11:00 PM

Third shift- 11: PM to 7:00 AM

For the office staff, timing is from is 9:00 AM to 5:00 PM.

Every day each employee works for eight hours in which 30 minutes is considered as break.

34 ORGANIZATIONAL STUDY

Page 35: Sarath

PRODUCTION MANAGER

SPINNING MASTER

ASSISTANT PRODUCTION

MANAGER

ASSISTANT MAINTENANCE

MANAGER

SUPERVISOR

WORKERS

ALLEPPY CO-OPERATIVE SPINNING MILL

6.2 PRODUCTION DEPARTMENT

STRUCTURE OF PRODUCTION DEPARTMENT IN ACSM

35 ORGANIZATIONAL STUDY

Page 36: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

In every organization production department is concerned with the activities related to the

production process carried on by the organization. Production process includes the process of

converting raw materials &other inputs in to usable out puts. i.e., as final finished product which

in return produces profit for the organization? .

Functions involved

Fixation of the standard upon which yarn must be produced, ie. It is usually represented

as Hank.

Operation of purchase and storage of materials.

Planning and controlling the operations.

Inventory and qualitative control.

In ACSM the yarn is produced from the cotton which is extracted from flowers of cotton

which are produced from various part of our nation. The production process includes the process

of converting raw materials and other usable and stable outputs as final finished product which in

return produces profit for the organization.

Yarn is made up of a number of plies, each ply being a single spun yarn. These single plies

of yarn are twisted in the opposite direction (plied) together to make a thicker yarn. Depending

on the direction of this final twist, the yarn will be known as S-twist or Z- twist. For a single ply,

the final twist is same as its original twist.

Two main type of yarn are; 1) Filament Yarn 2) Texturised Yarn

Production process of yarn is carried out by using various types of machines. Each process is

considered and carried out as separate units or sections. They are;

1. Blow Room

2. Carding Units

3. Comber

4. Simplex

5. Ring Frame

6. Cone Winding

7. Packing Unit

36 ORGANIZATIONAL STUDY

Page 37: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

Each unit consists of wide variety of machines which are placed in this mill based upon the

sequence in which the process progress in producing yarn from varieties of cotton. In this mill

layout being followed for production process is process layout.

Process layout means the alignment of similar machines and equipment which performs similar

function is placed in plant locations which are linked to other machines for completing the cycle

of production.

RAW MATERIALS OF ASCM

The Cotton required for the Alleppy co-operative spinning mill LTD mainly come from

Tamil Nadu and Andhra Pradesh cotton is the main raw material which is purchased by Kerala

state textile cooperation on behalf of the mill.

Raw material which reaches the mill in bundle from and it is carried bale. When the load

reaches the mill, authorities check, take samples from selected bundle and sent it to the head

office KSTC for testing to ensure the quality. The mill sent every day stock statement of cotton

to KSTC.

WASTE

Production process of yarn yield wide variety of waste which can be used for,

1. Noil used as yarn by allowing it to reprocessing process.

2. Hand waste used for workshops.

3. Flat strips used for surgical cotton.

4. Pnenumafils can be used again by allowing in reprocessing process

YARN

Yarn consists of strands of materials twisted together. Each strand is made up of fibers all

shorter than the piece of yarn.

A fairy high degree of twist produce strong yarn a low degree of twist produce softer, more,

custrious yarn and a very tight twist produces crape yarn. Yarn are classified any their number of

parts. A single yarn is made from a group of filament fibers twisted together.

37 ORGANIZATIONAL STUDY

Page 38: Sarath

Mixing & Blending

Blow Room

Combed Yarn

CARDING

Silver Lap Drawing

Ribbon lap Lap Former

Combing

Drawing 1

Drawing 2

Simplex

Spinning

Double

Market

Winding

Packing

Reeling

Bundling

Barling

ALLEPPY CO-OPERATIVE SPINNING MILL

PROCESS FLOW CHART

38 ORGANIZATIONAL STUDY

Page 39: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

PRODUCTION PROCESS

The main production process flow chart is shown in the figure the raw material used in

cotton. It is processed through various sections and final product is cones of different sizes.

(Generally 40’s 50’s). The production process takes place the following section.

MIXING

Cotton of different varieties is mixed together in a certain ratio according to its quality. The

mixed cotton for processing contains the desired quality in required ratio. The mixed cotton is

kept without disturbance for a maximum period of 24 hours for conditioning.

While mixing the following things should be kept in mind

Micronaire range as well as average of the cotton bales used should be same for all the

mixing of a lot.

Range as well as average color of the cotton bales used should be same for all the mixing

of a lot.

Range as well as average maturity coefficient of the cotton bales used should be same for

all the mixing of a lot.

BLOW ROOM

Blow room separates heavy foreign mattes like cotton seeds, leaf particles etc. by beating

and blowing. The mixed cotton is fed in the lattice of first machinery manually. The blow room

consists of 5 machines considered as the beating points connected each other pipelines. The

cotton beats up with spikes and lags thus the impurities are separated out of cotton. The cleaned

opened cotton pusses to the next department through chute.

CARDING SECTION

Carding machine cards cotton and clean it further with the help of rotating sharp wire points

and thus removes the hooks and wastes remaining in the cotton. The cleaned cotton condenses

and passes out through trumpet. The product is called sliver.

SLIVER LAP

39 ORGANIZATIONAL STUDY

Page 40: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

This machine is considered as the preparatory machine of comber. Silver from the card is fed

by giving 16 doubling is called Sliver Lap.

RIBBON LAP

Lap from the sliver lap is fed here and produces Ribbon Lap ,6 ends doubling is giving here.

COMBER

Thus machine removes short fibers from cotton y combing action with help of unicombs and

top combs. Combed sliver is the final product . The wastes extracted from comber, called noils

are a saleable product.

DRAW FRAME

The main function of this department is to parallelize the sliver and makes it even by drafting.

The card sliver lacks on regulating the fibers are also in a crisis condition.

SIMPLEX (SPEED FRAME)

This machine consists of 120 spindles and each spindle is a point of production. Sliver from,

120 cans fed to 1230 spindles respectively and by giving certain draft the silver is drafted to

some length. The sliver is passed through the drafting zone 12 to 13 times. Certain amount of

twist is imported on the body of drafted material, which is called ROVE EACH full bobbin of

40’s combs normally weight 1.25kg.

SPINNING (RING FRAME)

In the spinning department bobbins that are brought from the simplex department are reeled

on the ring frame reel and the Rove is drawn through the drafting zone. The main object of

spinning is drafting , twisting and winding . Rove is drafted to a thinner form of yarn. It is

drafted to 20 to 27 according to be spun.

CONE WINDING

The yarn cops carried to the winding department to produce yarn cone. In the cone

department all types of defects in yarn is rectified and also yarn on cone will be defect free. Yarn

from the cops is wound to bare paper cone .The standared weight of full cone is 1.25 kg . A

40 ORGANIZATIONAL STUDY

Page 41: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

winder has to look after 15-30 runs according to cone of 1.25 kg is removed and collected by the

winder and then it is stacked in the bins count wise in the packing department.

CONE PACKING

In this department the final product of yarn on cones are packed in polythene bags. One such

bag contains 40 cones and the Net weight of 1 bag is 50 kg. They put necessary details like

count, gross weight, month and year of packing, bag numbers in lot numbers .Then these bags

are ready for dispatch to the market or depots.

41 ORGANIZATIONAL STUDY

Page 42: Sarath

FINANCE MANAGER

SENIOR ACCOUNTANT

JUNIOR ACCOUNTANT

CASHIER

CLERCK

PEON

ALLEPPY CO-OPERATIVE SPINNING MILL

6.3 FINANCE DEPARTMENT

STRUCTURE OF FINANCE DEPARTMENT

42 ORGANIZATIONAL STUDY

Page 43: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

Finance may be defined as the provision as the money at the time is wanted. Finance is

regarded as the life of the blood of an organization. In current economy, finance is one of the

basic foundations of every kind of economic activity which is concerned with the planning and

controlling of the firm’s financial resources.

Finance department is headed by finance manager assisted by Senior Officer, and cashier.

The department is fully computerized and hence manpower is limited since all receipts and

payments are computerized. All the purchasing/quotation works are handled through online as

result of distance the financial transactions in ACSM are carried out with the help of computers.

The records maintained in the department include

Journal, LEDGER AND SUB LEDGER

Cash Book

Profit and Los Account

Balance Sheet

All the planning and controlling of firms financial resources are carried out by the finance

manager. The responsibilities of Financial Manager include.

Arrangements of funds from financial institutions

Managing funds raising program

Arrangements of funds through financial instruments such shares, debentures, bond etc.

The manager deals with the supervision and control of finance clerk deals with the sales

account and cash book and the laisoming officer is the cashier. Sum total the function performed

by finance departments in ACSM are

Preparation of balance sheet and cost sheet

Verification of vouchers bills etc

Preparation of budget and its analysis.

Budgetary control

Verification of cash balances

Passing all payment bills

43 ORGANIZATIONAL STUDY

Page 44: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

Preparation of various books and records

Preparation of bank vouchers and books

Maintenance of sales ledger and stores ledger

Maintenance of all subsidiary books like cash book, debtors’ book and sales ledger

STATUTORY ACTIVITIES

1. Contract payments and income tax payments.

2. Sales tax and vat collection and remission

3. Employee state insurance(ESI)

4. Income tax filling of queerly income tax return.

STORES

The stores department is under the control of finance department. The store is maintained by

the store keeper. In stores the employee will maintain frequents stock records and they will

inform to the finance department about the present inventory level and also the information will

be passed to the respective departments.

ACSM makes purchase through local purchase. In local purchase, the concerned officer in

charge sends enquiries to the different suppliers and invites a quotation. After that they will be

short listed and purchase order will be send to the supplier who had place the lowest price.

Stores department had provided separate go downs for both raw materials and finished goods.

Based on the need, material is purchased. Goods receiving wing receives the goods at the site

and verifies the same copy with the copy of purchase orders. If the goods received are as per the

description or purchase order. The stores department prepares the note called gods received note

and sends the same to stores department along with the materials.

44 ORGANIZATIONAL STUDY

Page 45: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

There is another receipt called the Stores Receipt Note (SRN) .This document is prepared

after the materials received are as per the order. The stores department prepares two copies of

SRN, the stores department retains one and the other is send to the finance department for

making payment to the suppliers. Once SRN is raised and materials are accepted the next step of

stores department is to take them to respective storage areas and they are issued to the

production department as and when the requisition is made by the later.

LIST OF ITEMS MAINTAINED IN THE STORES

PACKING MATERIALS

WOVEN SACKS

POLYTHENE COVER

BUNDLE LABEL

CORD LABEL

SUTHALI

PAPER CONE

CAP WITH SCREW

ENGINEERING GOODS

ELECTRICAL MACHINERY SPARE PARTS

MECHANICAL MACHINERY SPARE PARTS

LIST OF BOOKS MAINTAINED IN THE STORES

STORES LEDGER

STORES REGISTER

BILLS WITH CONCERNED GOODS RECEIVED NOTE

FUNCTIONS OF STORES

1. MAKE PROPER ARRANGEMENTS TO RETAIN THE GOODS IN PERFECT

CONDITION TILL THEY ARE NEEDED BY ANY OF THE USER SECTION.

2. MAINTAIN MONTHLY UPDATED STOCK LEDGER

45 ORGANIZATIONAL STUDY

Page 46: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

3. BRINGING TO NOTICE THE LOWER AMOUNT OF STOCK OF ANY KIND IN

STORES

46 ORGANIZATIONAL STUDY

Page 47: Sarath

OPENING STOCK

INWARD/ GOODS RECEIPT

NOTE

ISSUES/INDENTS

LEDGER LEDGER

MAINTAINING CLOSING STOCK ON WEIGHTED

AVERAGE METHOD

INTERNAL VOUCHER FOR

ISSUES

INTERNAL VOUCHER FOR

ISSUES

PROFIT AND LOSS ACCOUNT

ALLEPPY CO-OPERATIVE SPINNING MILL

DIAGRAMATIC REPRESENTATION OF DEPARTMENT FUNCTION

47 ORGANIZATIONAL STUDY

Page 48: Sarath

MARKETINGMANAGER

ASSIATANT MANAGER

DEALERS

AGENTS

CUSTOMERS

ALLEPPY CO-OPERATIVE SPINNING MILL

6.4 MARKETING DEPARTMENT

STRACTURE OF MARKETING DEPARTMENT

The target market of ACSM is the Mumbai market from there these products are

purchased by business concentrated on textile sectors. In order to avoid the ware housing and

storage in Mumbai these products are transferred to agents present in Mumbai that is ACSM

products are marketed through “Depot marketing”.

Depot marketing means the agents act as intermediaries. ACSM provides 1.5% of

commission to these agents .they sell the yarn o0n the basis of the present market value. the

agent purchases yarn from the mill and provides this yarn to the concerned parties. the payment

is made only after the selling procedure is complete

ACSM has 2 agents in Mumbai .they are Ramalingalkaland Nandalal brothers and

sathyam enterprise. ACSM market their product to certain parts of Kerala like kottayam,

Ernakulum and alleppy.

The cotton purchased from various state of India such as Punjab, Maharashtra etc. it is

mainly done by inviting quotation through online. The main products of ACSM are carded yarn,

48 ORGANIZATIONAL STUDY

Page 49: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

combed yarn and hank yarn .among the combed yarn possesses the highest demand in the

market.

MARKETTING RESEARCH

A research about the marketing opportunity of the product of ACSM inside Kerala is not

worth because the firm is marketing its products mainly outside Kerala and that to through depot

marketing. But research is being done under the supervision of SITRA in various parts of north

India mainly in the markets of Punjab, Karnataka and tamilnadu. These led to the conclusion that

cotton mills in Kerala, has to market standardized machineries for facing competition from other

states.

MARKETING INFORMATION SYSTEM

Agents placed outside our state are the main source of marketing information for ACMS.

Since no marginal retail price can be fixed on the fiber yarn produced in ACSM , the changes in

the market price and the condition are known in advance to the firm by the agents . Other than

these marketing opportunities for the products in ACSM.

PRICING STRATEGY

One of the most important factors relating to fiber yarn is that no fixed marginal retail

price(MRP ) can be printed on the fiber yarn. Thus the firm is forced to sell the product at the

market price of the fiber yarn. Having known the changes that can happen in the market well in

advance, the firm is able to stock raw materials to be used in favorable conditions and thus

maintains the profit.

49 ORGANIZATIONAL STUDY

Page 50: Sarath

SPINING MASTER

ASSISTANT SPINNIG MASTER

DEPARTMENT TECHNICIAN

TESTING LAB

SUPERVISORS

ALLEPPY CO-OPERATIVE SPINNING MILL

6.5 QUALITY CONTROL DEPARTMENT

STRACTURE OF QUALITY CONTROL DEPARTMENT

QUALITY MANAGEMENT

Quality management is the watch word in modern industry as it affects the user need as

well as profitability. To help efficient functioning of quality control, the method and procedure

that need to be adopted have been well formulated and systemized for long.

In ACSM, the quality management is carried out with the help of SITRA Coimbatore.

The ultimate quality yarn is based on the raw material ie, quality of cotton used. The quality of

cotton purchased is given to the Central Testing Centre Trivandrum

50 ORGANIZATIONAL STUDY

Page 51: Sarath

ASSISTANT SPINNING MASTER

TESTING LAB

DEPARTMENT TECHNICIAN

SUPERVISORS

SPINNINGMASTER

ALLEPPY CO-OPERATIVE SPINNING MILL

The basic problem in ACSM is the manufacture of a standard product from an

essentially nonstandard and highly variable raw material. The quality of yarn should conform to

certain accepted norms depending on the end use . It is equally important that this is achieved at

the minimum cost possible. Norms and standards for quality are fixed by the mill for quality is

fixed by the mill for all the raw material.

In order to have effective quality control there should be an officer exclusively in charge

of quality control. Here in ACSM spinning master who looks after this aspects along with him

there are two laboratory testing assistant and for data collecting from various departments.

The communication pattern followed in ACSM with regard to control is as follows:-

Quality management is the act of screening the defective before they reach the customer. Quality

control is done as a cycle taking place in the production department. Scientific sampling , design of

experiments, the analysis, the presentation and interpretation of data through statistical techniques all

these creates the cycle the process taking place during the process of quality management.

Statistical techniques are useful in determining sample size, fixing natural limits of variations of

the process, deciding frequency of inspection, testing conformity of sample to specification as provided.

51 ORGANIZATIONAL STUDY

GENERAL MANAGER

Page 52: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

In many manufacturing process the two articles produced willn’t be the same all the time. So therefore in

every unit the process control test are applied in order to check the quality of yarn produced at each stage.

Generally the unevenness of the yarn is expressed in terms of U%/CV%. The short term

irregularity of yarn is determined by assessing the user U% which is a measure of the variation in the

weight of 8mm cut length of the yarn. CV is the coefficient of variation of mass with cut length of 10mm.

The SITRA has specified some norms with respect to short term irregularity of yarns.

TYPE COUNT GOOD AVERAGE POORCARDED 20S 12 13.5 15

30S 12.5 14 15.540S 14.5 16 17.560S 15 17 1880S 16 12 19

COMBED 30S 11 12 1340S 12 13 1460S 12.5 13.5 14.580S 13 14 15100S 13.5 14.5 15.5

QUALITY SYSTEM STANDARD

A spinning mill where yarn is produced as per the customer’s requirement implemented

ISO 9002 and ISO 9003 models. ISO 9001 model is more appropriate for mills producing special

yarns and fabrics for industrial applications where the fabrics have to be engineered to meet very

string requirements. Here in ACSM both these ISO 9000 standard are being applied with respect

to the production of yarn.

ISO 9002

This standard is applicable for the industries where the specified requirements of

products/services are stated in terms of established design parameters. The ACSM, which

is involved in the manufacturing process of yarns, fabrics etc as per the customers

requirement follows the path these standards.

ISO 9003

This standard specifies quality system requirements for situations which require demonstration

of suppliers capability to detect and control the disposition of any non conformality during final

inspection and test .ACSM, which is involved in purchasing of raw material, testing the samples

52 ORGANIZATIONAL STUDY

Page 53: Sarath

TQM

ALLEPPY CO-OPERATIVE SPINNING MILL

is grading them as per the properties and selling them to the market. All these process are done

according to ISO 9003.

The quality management system implemented in ACSM Ltd, kayamkulam is Total Quality

Management (TQM). Basically TQM is the process of achieving customer requirements

at the lowest effective cost by bringing out talents of the employees. TQM stands for

management approach of an organization, centered on quality based on the participation

of all its members and aiming at long term success through customer satisfaction and

benefits to all members to the organization and society.

The quality management under TQM involves several steps. These steps are being

implemented in ACSM as management system. They can be schematically showed as;

ISO 9000 BPR AND BPB

IMPLEMENTATION

IMPROVEMENT TEAM CHANGE MANAGEMENT

1. BPR –BUSINESS RE-ENGINEERING

2. BPB-BUSINESS PROCESS BENCH MARKETING

53 ORGANIZATIONAL STUDY

Page 54: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

.

CHAPTER -7

ANALYSIS

54 ORGANIZATIONAL STUDY

Page 55: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

SWOT ANALYSIS

In SWOT analysis the Strength, Weakness, Opportunities, Threats of ACSM Ltd, kayamkulam is

analyzed and noted.

It is a tool that identifies the strength, weakness, opportunities and threats of an organization.

Specifically, SWOT is a basic, straightforward model that assesses what an organization can and

cannot do as well as its potential opportunities and threats.

The method of SWOT analysis is to take the information from an environmental analysis and

separate it into internal (strength, weakness) and external issues (opportunities, threats). Once

this is completed, SWOT analysis determines what may assist the firm in accomplishing its

objectives, and what obstacles must be overcome or minimized to achieve desired results.

STRENGTHS

Goodwill of the company

Government Co-operative

Good employer-employee and employee-employer relationship

Only few competitors in India

Leaders are available round the clock in case of plant emergencies

Service oriented

Most of non-core areas outsourced canteen, excellent housekeeping practices, restrooms

etc.

Good relation with the distributors and customers

Highly committed staff

Attendance time punching including all

Computerization in each and every department

Kept technical document for all technical policies

55 ORGANIZATIONAL STUDY

Page 56: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

WEAKNESS

Mill is highly depending on the availability of cotton as raw material from other state of

India

The main customer of ACSM is in Mumbai business man’s who deals with the textile

sectors

There is no fixed MRP like every other product

Transportation charge block its proper functioning

Production work will be shut down due to lack of raw material, cotton due to

unpredictable natural causes

OPPORTUNITIES

Prosperity of the industry in both domestic and export front

Helpful to framers can increase income from cotton cultivation

The decision of the government to start working up of 6000 spindles only at first stage

Financial assistance provided by TEXFED

Most advanced automatic power law and competent technical man power

The local market should be utilized to promote sales

THREATS

The main threat of ACSM is its competitors especially from the china and srilanka in these

countries labor charge is very less compared to India

Decline in cotton yarn export

Lack of modernization

Lack of local market for raw materials and finished goods

Non-availability of credit

Low availability of raw material

Increase in cost of production through dual transportation

Labor shortage due to pay scale provided by the company

Trade Liberation

56 ORGANIZATIONAL STUDY

Page 57: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

CHAPTER -7

FINDINGS AND SUGGETIONS

57 ORGANIZATIONAL STUDY

Page 58: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

Findings and Suggestions

Customer is fully satisfied with the product quality

Product distribution is going very fastly and there is no delay in supply of products to the

markets

Cost of production is high

Rate of interest of loan is very high as compared to agricultural industry

The company is environment friendly

Better industrial relationship

Qualified and skilled workers

No suggestion boxes for employees

There are only few competitors in India

Most of the employees are appointed on the basis of contract, therefore no job security

among them

Low availability of raw materials

Good refreshment facility in the organization

During harvest season huge amount have to be paid for cotton

SUGGESTIONS

Provide more job security by appointing workers on permanent basis

Provide suggestion boxes

ACSM should be computerized and linked with all departments

Provide uniforms for the employees that may help to create feeling of uniformity

Effort should be taken to maintain a sound balance between tradition and modernization

Provide mask and head cover

Since office not fully furnished the space requirement of each department is not met

To increase the availability of cotton in various sources.

58 ORGANIZATIONAL STUDY

Page 59: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

CHAPTER -8

CONCLUSION

59 ORGANIZATIONAL STUDY

Page 60: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

CONCLUSION

In this organization study at ACSM gave a lot to study and understand the

mannerism of putting theoretical frame work in to practice. The objectives of this study

were acquiring knowledge about the functional as well as managerial aspects and the

origin and history of the company. Through this organization study a practical experience

in the different organizational activities was made.

The organization study has helped to understand more about textile industry and the

major threat faced by the industry. It also helped me to understand the fact that textile and

clothing industry is the single most earners around 30% of gross export earnings for India

holds the second position in the world market in the field of yarn. This organization is

absolutely suitable for the climate of Kerala. In 2010ACSM was selected as model Mill

by RIAB

But the number of textile industry in south India declining day to day. It mainly due

to the non-availability of credit and lack of modernization in the field of production. The

uncertain risk behind the raw material that is cotton is one of the main threads of this

industry. In ACSM the raw materials being brought from Andra Pradesh, Maharashtra

Tamil nadu, Punjab etc at the same time the finished goods is also transported outside the

state which lead to the high production cost.

If the industry is able to overcome these threats then it this sector would provide

more job opportunities in the industrial as well as agricultural sector.

60 ORGANIZATIONAL STUDY

Page 61: Sarath

ALLEPPY CO-OPERATIVE SPINNING MILL

BIBLIOGRAPHY

BOOKS

Philip Kotler, Marketing Management, Pearson prentice Hall

Dr. Madhur B.S, Co-operation India, Sathiya bhavan publication Distribution Pvt Ltd.

Pandey I.M., Financial Management, Vikas Publication.

Websites

www.ask.com

www.cotton. Com

www.textile.com

61 ORGANIZATIONAL STUDY