Summer Internship Report - Vardhman

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O

Ravi Shekhar SEM-V, NIFT DELHI Auro Spinning Mills Hall 5

TABLE OF CONTENTS ACKNOWLEDGEMENT 1 VARDHMAN GROUP 2 INTROUCTION 2.1 MANUFACTURING 2.2 PORTFOLIO 2.3 ADMINISTRATION 2.4 QUALITY POLOCY 2.5 PHILOSOPHY 2.6 AURO SPINNING MILLS 3 PRODUCTION DETAILS 3.1 AURO LAYOUT 3.2 RAW MATERIAL STORAGE AND FIBER INSPECTION 3.3 PROCESS FLOW 3.4 BLOWROOM 3.5 CARDING 3.6 DRAWING 3.7 LAP FORMER 3.8 COMBING 3.9 FINISHER DRAW FRAME 3.10 DRAW FRAME 3.11 SPEED FRAME 3.12 RING FRAME 3.13 WINDING 3.14 PACKING 3.15 SPIN CALCULATION & PLANNING PRODUCTION 4 GOAL OF THE PROJECT 4.1 THE PROPOSAL 4.2 AN INTRODUCTION TO NEW SYSTEM 4.3 ASSESMENT OF CURRENT SYSTEM 4.4 SILENT FEATURES OF NEW SYSTEM 4.5 TECHNICAL REQUIREMENT FOR NEW SYSTEM 4.6 DEVELOPERS REQUIREMENT 4.7 DATA FLOW DIAGRAM 4.8 UNIT CONVERSION AND SPIN CALCULATION 4.9 MAINTENANCE : UPDATION & SUPPORT 4.10 SNAP SHOTS 4.11 BIBLIOGRAPHY 5 2 3-6 3 3 5 5 6 6 7-27 7-8 9 10 11 12-15 16-17 18 19 20-21 22 23 24 25 26 27 28-46 28 29 30 31 33 34 35 36 37 44 45 47

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ACKNOWLEDGEMENT | This Internship Proved to bridge the gap between the theoretical and Practical Aspects of textile Field. It was a great pleasure to be part of Vardhman Group. All Thanks to my institute NIFT, New Delhi for providing me the opportunity for getting the practical knowledge at such an eminent company. I am also greatly thankful to my subject faculty Dr. Senthil Venkat for the full support and step-by-step assistance. I am also Thankful to my Internship Mentors Dr. Noopur Anand and Ms. Suruchi Mittal. I am very thankful to the whole Vardhman Group for providing me the best possible facilities and good environment during the period of my internship. I acknowledge deep gratitude towards each and every employee of the Auro Spinning Mills, Baddi for providing me with their valuable time. I would also like to express my gratitude towards my mentor Ms Parul (HRD) and Project Guide Mr. Punit Singhal (R&D) for giving me chance to work on such a nice project. I pay my thanks to Mr. Vipin Sachan, Mr. Sunil Mishra and Mr Harpeet Rana (Shift Officer, Unit 5) who gave his valuable time and attention during my training and completion of project report.. Instructions of each person I meet in Auro were very beneficial for the successful completion of my project report. I pay my special thanks to all the other HODs also for their valuable time, co- operation,, guidance and providing useful data, namely Mr Ravindra Yadav (R&D), Mr Devendra Vasist(R&D) and Un-doubly Mr Ravi Ranjan (TPM) for his all source of inspiration all along.

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Spin

Weave

Process

VARDHMAN GROUP 2|TWO Vardhman is a leading conglomerate with interests in textiles and steel having a turnover of Rs.2100 crores. The Vardhman group comprises six companies and twenty production units located in Punjab, Himachal Pradesh and Madhya Pradesh. A growth rate of almost 15% per year in turn over the last five years has been reflected in the financial results of the group. MANUFACTURING 2.2|TWO Vardhman group consists of integrated facilities of spinning, weaving and finishing. By and large it has a strong focus on textiles, which remains the largest industry in our country. Over 8, 00,000 spindles 65 tons per day yarn and fiber dyeing 900 shuttle-less looms 90 million meters per annum processed fabric 33 tons per day sewing thread 18000 metric tons per annum acrylic fiber 100,000 tons per annum special and alloy steel Vardhman started its operation in 1965 from Ludhiana with a modest capacity of 14000 spindles. Today 5, 00,000 spindles which is largest any single group has in India. Besides it has weaving capacity of 264 looms and fabric finishing capacity of 95,000 meter per day. In addition it has mercerizing and dyeing of yarn and fiber and an acrylic production unit at Gujarat.

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MANUFACTURING UNITS 2.2.2|TWO Vardhman group consists of integrated facilities of spinning, weaving and finishing. By and large it has a strong focus on textiles, which remains the largest industry in our country. Vardhman Spinning and General Mills Ltd. Vardhman Spinning and General Mills Ltd. Ludhiana Auro Spinning Mills Baddi, H.P. Auro Dyeing Baddi, H.P. Auro Weaving Mills Baddi, H.P. Auro Textiles Baddi, H.P. V.S.G.M. 100% E.O.U. Baddi, H.P. V.S.G.M. Unit 2 Ludhiana V.S.G.M. Unit 3 Ludhiana Mahavir Spinning Mills Ltd. Mahavir Spinning Mills Ltd. Hoshiarpur Arihant Spinning Mills Malarkotla Anant Spinning Mills Vardhman Special Steel Lidhiana, Punjab M.S.M.L. Sewing Threads Unit 2 Ludhiana, Punjab Arist spinning Mills Baddi, H.P. Arist Spinning Mills 100% E.O.U. Baddi, H.P. Vardhman Polytex ltd. Vardhman Ploytex ltd. Bhatinda, Punjab Anshupati Textiles Ludhiana, Punjab V.M.T. Spinning Co. Ltd. Baddi, H.P. Vardhman Acrylic Ltd. Bharuch, Gujrat Vardhman Threads Ltd. Baddi, H.P.

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PORTFOLIO 2.3|TWO

Actual 2008-09

Group Total USD Million ( crores) 329 150 73 71 47% 22% 11% 10% % Share

Business Wise TurnOver for Financial Year 2008-2009Yarn 47%Yarn Fabric Sewing Thread

1513 689 337 327

Fabric 22% ST 11% Steel 10%

Fiber 8%

Steel

Power plant

66

14

2%

Power Plant 2% Steel Yarn

Fibre

254

55

8%

Fiber ST

PowerPlant Fabric

Total

3186

693

100%

ADMINISTRATTION 2.4|TWO Corporate office located in Chandigarh road in Ludhiana adjacent to Vardhman Spinning and General Mills Ltd.(Ludhiana). It came into being in 1995. Vardhman Group has administrative and marketing branches all over India and in more than 20 countries for its various businesses. The group is well diversified in making sewing threads, fabrics, hand knitting yarns, cotton yarns, acrylic yarns etc. with a capacity of over 5,00,000 spindles and 264 looms producing yarns and fabrics. Shree S.P. Oswal, a gold medalist in M.Com. heads the group who is the chairman and managing director of all group companies.

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QUALITY POLICY 2.5|TWO 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.

PHILOSOPHY 2.6|TWO

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AURO SPINNING MILLS (77904 SPINDLES)Auro Spinning Mills Baddi (Himachal Pradesh)

3|THREE77904

Auro weaving mills, a weaving subsidiary of Vardhman Spinning and General Mills Limited, has now emerged as one of the premium companies in India.

PRODUCTION DETAILS 3.1|THREEProduction Halls Production Units 5

UNIT 1 (HALL1) 3.1.1|THREE

Manufacturing Activity Greige Cotton ( both cared & combed) and core spun with lycra. Unit Capacity Product Range 24,422 spindles Production of yarn per day: 16,000 kg

10s-60s

UNIT 2 (HALL 2) 3.1.2|THREE

Manufacturing Activity Sliver preparatory and sample line Unit Capacity Product Range 1382 spindles Production of sliver per day: 9,000 kg

Lycra, compact, compact+lycra, slub+lycra, slub, Blends

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UNIT 3 (HALL 3) 3.1.3|THREE

Manufacturing Activity Unit Capacity Product Range

Cotton and lycra (bulk orders) 38592 spindles Lycra, slub, fancy yarns

UNIT 4 (HALL 4) 3.1.4|THREE

Manufacturing Activity Open- end yarn Unit Capacity Product Range 6s-20s 1248 rotors Production of yarn per day: 12,000 kg

UNIT 5 (HALL 5) 3.1.5|THREE

Manufacturing Activity Unit Capacity Product Range

Compact ( Elite) spun yarn 14256 spindles Production of yarn per day: 4000 kg 40s-200s

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AURO LAYOUT 3.2|THREE

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RAW MATERIAL STORAGE AND FIBER INSPECTION 3.3|THREE BALE SPECIFICATION 3.3.1|THREE Fiber Net Weight Origin/Supplier Length Width Staple length BALE INSERTION PARAMETER 3.3.2|THREE Origin: Thickness or Fineness (micronaire) Bale weight: 165 or 220 kgs (approximately). Staple length: 30-35mm Degree of Reflection (RD): 60-80Degrees Strength : 24-29 gram/tex Moisture regain Evenness Maturity MACHINE USED FOR TESTING OF FIBER 3.3.3|THREE HVI: High Volume Instrument AFIS: Advance Fiber Information System

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PROCESS FLOW 3.4|THREE

Godown

Mixing (MBO)

Sorting (Manualy)

Carding

Blow Room

Bale Formation

Pre-Combing

Combing

Drawing (F D/F)

Winding

Ring Frame

Speed Frame

Conditioning

Packing

Dispatch

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BLOW ROOM 3.5|THREE INTRODUCTION 3.3.1|THREE Blow-room consists of a number of machines used in succession to open and clean the cotton fiber. About 40% - 70%