A STUDY ON SOWMIYA SPINNING MILLS AT COIMBATORE

CHAPTER I

INTRODUCTION

The glorious Indian industrial past was related with cotton and silk goods, jewels, embroideries
etc. After independence, large scale industries especially in consumer goods like cotton textiles, jute
and sugar had registered significant growth. Large scale industries are those which require huge capital
investment and long growing period.

Among all the subsectors of the textile industry, spinning is perhaps the most modernized
segment. Production in fiscal 2008-09 (April-March) was 3,049 million kg, of which 2,205 million kg
was pure cotton yarn and the rest was synthetics and blends, such as polyester/viscose; polyester/cotton
and spun acrylics. The industry exported about 540 million kg of cotton yarn and about 100 million kg
of blended yarn, which together works out to about a fifth of the total output.

The spinning industry grew at a very rapid pace in the first half of the nineties. Thereafter
growth slowed to some extent but through the nineties, India has installed nearly 15 million spindles.

Large scale industrial sector is one of those sector that paved the way for economic growth in a
country like India cotton industry is a major large scale industry and contributed one fifth or 20% of
the total industrial output of the country.

The cotton textile industry has three main divisions. They are:-

1) The mill industry producing yarn & cloths

2) The power loom factories producing clothes from mill made yarn

3) Widely dispersed handloom units producing cloth both from mill made and hand spun yarn.

The present study of an organization like SOWMIYA SPINNING MILLS AT

COIMBATORE one of the leading cotton spinning unit in COIMBATORE District, is an eye opener
to the various obstacles being faced and the future prospect of industry.
OBJECTIVES OF THE STUDY

The project apart from a brief overall review of the organization, referring the general
activities of both the managerial and non-managerial level of the organization. The main issue of
concern related to the practical difficulties and management practices carried out during the
entire process of the production of the product and also the organizational behavior towards
various issues arising during the production activities are concentrated in this study. The other
aspects of the study are enlisted below.

 To study in detail the entire structure and functioning of the company

 To make an analysis of the organization’s performance.
 To know the Company Profile
 To understand how the key business process are carried out in organizations
 To understand about the functioning of each department in detail.
 To understand the extent to which management theory matches with actual practices.

NEED FOR THE STUDY

This study is basically focused on understanding the practical exposure in the industry and not
for data and information i.e. to experience the firsthand knowledge about how an organization is
being run.

 To identify and understand the practical work process followed in an organization

 To understand various practical difficulties faced in an organization and how its solved in a
profitable manner.
 To study and prepare an organization chart of an organization and to understand the
functions of the organization at various departments at each level.

 To interact with the personnel’s and workers (both external & internal) to find if there are
problems with the process and record the findings.
 To undergo a brief study on the following management aspects :
SCOPE OF THE STUDY

Good Management Practices and Organizational Functionality is an important factor for

any Organization to achieve the desired goals and Objectives. This study allows knowing about
the overall perspective and performance of COTTON SPINNING MILL Industries in India and a
basic practical study on SOWMIYA SPINNING MILLS AT COIMBATORE.

As a part of MBA program at the end of 1st semester, I had to carry out a project on an
organization study in order to understand the organization structure and their functions. This
creates a handful of opportunity to get the first hand information and understand the functioning of
an organization in the practical world.

SIGNIFICANCE OF THE STUDY

In today’s world, business has become more and more competitive and the technology has
changed the nature of business and organization. This study analyses in detail about the functions of
different departments on the basis of which strength, weakness, opportunity, and threats are arrived
at. The findings of this study would give valuable information for improving the overall performance
of the organization.

LIMITATION OF THE STUDY

 The busy schedule of the department heads restricted the collection of detailed
information.
 Time to time company meetings also restricted the visit to several departments.
 The confidentiality restricted the collection of financial accounts.
 The information given by the persons may not be complete because of their busy work
schedules

CHAPTER II

INDUSTRY PROFILE AND COMPANY PROFIEL

INTRODUCTION

SPINNING MILL

A spinning mill is a labour intensive industry and it provides ample job opportunities. sowmiya
spinning mills is a unit of the subsidiary of ntc. The registered office of apkk & m is located in
bangalore. At present the capacity of the sowmiya spinning mill has increased to 25920 spindles.
the company is a spinning mill with weaving facilities. But currently no weaving process is
going on in the mill.

Spinning mills used ‘Line Shafting’ which is the means by which the power of the steam engine
is transmitted along rotating shafts (rods) to the spinning or weaving mills. Now, however
electricity is being used which is much faster than hand spinning. Yarn is the final product of the
mill. To maintain the quality aspects an efficient quality control team functions in the mill.

Every organization needs to have well-trained and experienced personnel to perform the
activities that have to be done. If the current or potential job aspirant can meet the requirement,
training is not important. But when this is not the case, it is necessary to raise the skill levels and
increase the versatility and adaptability of employees. Inadequate job performance or a decline in
productivity or changes resulting out of job redesigning of technological changes requires some
type of training and development efforts. As the jobs become more complex, the importance of
employee development also increases

THE TEXTILE MILL INDUSTRY

Cotton/man-made fibre textile industry is the single largest organized industry in the country
employing nearly 10 Lakh workers. Besides this, there are large numbers of ancillary industries
dependant on this sector such as those manufacturing various machinery, accessories, stores
ancillary and chemicals. Even on a modest assumption that a workers family comprises of five
persons, the direct dependents on the organized mill industry itself works out to about 50 Lakhs.

Out of the 1837 cotton/man-made fibre textile mills, 192 mills are in the public sector, 154 mills
in the co-operative sector and 1491 mills are in the private sector.

EVALUATION OF THE TEXTILE MILL INDUSTRY

Whilst farmers were developing new and better methods of agriculture, life in other areas of
work had changed little for hundreds of years. Early in the 18th century most of the population
lived in small rural settlements and only a few people lived in town.

Many people worked as producers of woolen and cotton cloth. They cleaned, combed, spun,
dyed and wove the raw materials into cloth and this work was done in their own houses. This
type of production has become known by the general term of domestic (cottage) industry. Work
within the cottage industry was usually divided up between the members of one family. The
women and girls were responsible for cleaning the sheep fleeces, carding the wool and spinning
it.

The process of weaving was physically hard work and traditionally it was the men who were
responsible for it. Generally at regular intervals a cloth merchant visited each handloom weaver’s
cottage. He would bring the raw materials and take away the finished cloth to sell at the cloth
hall.

As soon as the new wool arrived, it was washed to clean out all the dirt and natural oil. After this
it was dyed with colour and carded. This was the process of combing the wool between two
parallel pads of nails, until all the fibres lay the same way. Next the carded wool was taken by
the spinner and using a spinning wheel the thread was wound onto a bobbin.

The spun yarn was taken to the loom to be woven. In the weavers cottage the loom was often to
be found on an upper floor. There are large windows in the room to let in plenty of daylight.
Working of the loom was quite strenuous work, which is why it was traditionally the work of the
men of the household.

However, with the advent of the industrial revolution all the processes of yarn and the
subsequent production of cloth underwent a dramatic change. The industrial revolution brought
about the wide spread replacement of manual labour by machines. Goods that were traditionally
been made in the homes or in the small workshops began to be manufactured in factories.
Productivity and technical efficiency, improved in part through the systematic and practical
knowledge of the manufacturing process.
Spinning is the process of creating yarn (or thread, rope, cable etc.) from various rows of fibre
materials. Several fibres are twisted together to bind them into strong, long yarn. Characteristics
of the yarn vary based on the materials used, fibre length and alignment, quantity of fibre used
and degree of twist. The earliest spinning probably involved simply twisting the fibres with the
hand. Later the use of stick to help twist the fibre was invented.

The spinning wheel was then developed which allowed continuous and faster yarn production.
Spinning wheels are either foot or hand powered. Modern powered spinning used line shafting,
which is the means by which the power of the steam engine is transmitted along the rotating
shaft to the spinning or weaving mills. Now, however, electricity is being used which is vastly
faster than hand spinning.

Another major invention was the power loom. The power loom was a steam powered
mechanically operated version of a regular loom, an invention that combined threads to make
cloth. In 1785, Edmund Cartwright patented the first power looms and set up a factory in
Doncaster, England, to manufacture cloth. William Horrocky and Francis Cobot Lowell
improved it upon.

Francis Cobot Lowell was an American businessman and the founder of the world’s first textile
mill. Together with inventor Paul Moody, Lowell created a more efficient power loom and
spinning apparatus.

All this accelerated the growth of the mill industry with more production capacity, and the
labourers employed in the industry, rising to millions.

PRESENT SCENARIO

Global trade in textile and apparels is expected to increase from US $ 356 billion in2003 to US $
600 billion by 2010. The way forward for the textile mill sector is through transforming the
sector from a resource intensive to knowledge intensive, highly innovative sector with high
added value products and services. This can only ensure sustainable growth and jobs in the
future. It would also help to secure a competitive advantage, which would be based on the best
new products and processes in the world. The industry has made tremendous efforts in the last
years to invest in new productive assets, to streamline operations and to intensify their
innovation activities. To achieve a transformation, investment is needed in technological
innovations that would assist industry in its transition from resources intensive to a knowledge
intensive sector.

THE INDIAN TEXTILE INDUSTRY – A LEGACY OF ITS OWN

The Indian textile industry has a great legacy, which is perhaps unmatched in the history
of India’s industrial development, India’s textile industry evolved and developed at a very early
stage and its manufacturing technology was amongst the best. India’s manually operated
machines were among the best in the world and served as a model for production of the first
textile machines were among the best in world served as a model for production of the first
textile machines in newly industrialized Britain and Germany. India’s textiles were sought after
for their finesse, quality and design and attracted people from across the globe like the Chinese,
Malaysians, Portuguese etc. Colonization put an end to India’s glorious textile legacy. By 1880,
the domestic market had grown to be served solely by the British manufactures. One of the
aspects of freedom struggle led by Mahatma Gandhi was to weaken the British textile industry
by weaving homespun clothes, as he was convinced that the textile sector would be a catalyst in
advancement of the Indian population.

Post independence, till 1980, the Government of India put numerous restrictions to ensure
mechanization did not occur, labor intensive textiles were produced, which in effect led to
increase in price, and decrease in productivity.

COMPANY PROFILE

Sowmiya Spinners Private Limited is a Private incorporated on 09 September 2002. It is

classified as Non-govt company and is registered at Registrar of Companies, Coimbatore. Its
authorized share capital is Rs. 190,000,000 and its paid up capital is Rs. 189,000,000.It is inolved
in Spinning, weaving and finishing of textiles.

Sowmiya Spinners Private Limited's Annual General Meeting (AGM) was last held on 29
September 2017 and as per records from Ministry of Corporate Affairs (MCA), its balance sheet
was last filed on 31 March 2017.

Directors of Sowmiya Spinners Private Limited are Bhagavathi Mohankumar,

Muthusamychettiar Chinnadurai, Susheela Chinnadurai and Kariyagoundanur Chinnadurai
Karthik.

Sowmiya Spinners Private Limited's Corporate Identification Number is (CIN)

U17111TZ2002PTC010311 and its registration number is 10311.Its Email address is
sowmiya_spinners@rediffmail.com and its registered address is 6/203, Kovai Road,
Kariyampalayam Post, Annur Coimbatore TN 641653 IN , - , .

Current status of Sowmiya Spinners Private Limited is - Active.

Company Details

CIN U17111TZ2002PTC010311

Company Name SOWMIYA SPINNERS PRIVATE LIMITED

Company Status Active

RoC RoC-Coimbatore

Registration Number 10311

Company Category Company limited by Shares

Company Sub Category Non-govt company

Class of Company Private

Date of Incorporation 09 September 2002

Age of Company 15 years, 9 month, 21 days

Activity Spinning, weaving and finishing of textiles.

Number of Members 25

Share Capital & Number of Employees

Authorised Capital ₹190,000,000

Paid up capital ₹189,000,000

Number of Employees 500

Listing and Annual Compliance Details

Listing status Unlisted

Date of Last Annual 29 September

General Meeting 2017

Date of Latest Balance 31 March 2017

Sheet

Director Details

DIN Director Name Designation Appointment

Date

05165729 BHAGAVATHI MOHANKUMAR Director 20 May 2012

01645073 MUTHUSAMYCHETTIAR Managing 09 September

CHINNADURAI Director 2002

02401075 SUSHEELA CHINNADURAI Director 09 September

2002

06843931 KARIYAGOUNDANUR CHINNADURAI Director 12 March 2014

 KARTHIK

OUR VISION

 To manufacture products comparable to international standards, to be customer-focused

and globally competitive through better quality, latest technology and continuous
innovation.
 To transform the company into a modern and dynamic yarn, cloth and processed cloth
hand finished product manufacturing company with highly professionals and fully
equipped to play a meaningful role on sustain able basis in the economy of Tamilnadu.
 To transform the company into a modern and dynamic power generating company with
highly professionals and fully equipped to play a meaningful role on sustainable basis in
the economy of Tamilnadu

OUR MISSION

 To manufacture world-class products of outstanding quality that gives our customers a

competitive advantage through superior products and value, so we can make every
customer smile.
 To encourage people's ownership, empowerment and working under team structure.
 To attain highest level of efficiency, integrity and honesty
 To provide quality products to customers and explore new markets to promote/expand
sales of the company through good governance and foster a sound and dynamic team, so
as to achieve optimum prices of products of the company for sustainable and equitable
growth and prosperity of the company.

OUR VALUES

 Customer's satisfaction and delight.

 Superior quality of performance.
  Concern for the environment and the community.
 Passionate about excellence.
 Fair to all.
 To provide a safe workplace and promote healthy work habits

QUALITY OF INDUSTRY

Improving and maintaining quality of our products is of paramount importance. To ensure

consistent supply of good quality yarn, we follow a comprehensive quality control management
system.

We have well equipped laboratories for fiber & yarn testing and color matching & testing.

1. Quality Management System - ISO 9002

2. Foreign Matter -Manual sorting
3. Contamination- Vision Shield in Blow Room Siro Cleaner in winding stage
4. Fibre Quality - HVI
AFIS
5. Yarn Quality Uster Tester 3
Uster Tensorapid 3
Classimat II
Twist Tester
Uster Autosorter III
6. Colour Matching - Data Colour
7. Winding - SSM precision winders
8. Environment Management System ISO 14001 (.)

OBJECTIVE OF THE INDUSTRY

The goal for the department is to become a world class academic department in fashion and,
textile education, research and knowledge transfer with the following taken as the key objectives
for ITC from 2009/10 and onwards:
  To provide professional education covering the whole spectrum of activities in fashion
and textiles, and develop “all-round” graduates with vision and a global outlook, a sense
of social responsibility, critical and creative thinking ability
 To conduct research to create and disseminate knowledge to the academic community,
commerce, industry, society and the world at large
 To continue the review of academic programmes in fashion and textiles
 To further enhance learning and teaching in both teaching methodology and practice, the
implementation of outcome-based learning, maintain and upgrade an environment that
facilitates learning, with an aim to stimulate students’ interest in learning
 To collaborate with partners on the development of preferred continuing education in
fashion and textiles
 To become an area of excellence in fashion and textile education and research, regionally
and internationally
 To lead and enhance the development of the fashion and textile industry

OBSERVATION

 The current industry size comprises domestic market of US$ 68 billion and exports of
US$ 40 billion GLOBAL TRADE IN TEXTILE
 The country's textile industry, is currently estimated at US$ 108 billion otal global
textiles exports was to the tune of US$ 772 billion in 2013, with India’s textiles exports at
US$ 40 billion (5.2% market share) & CLOTHING SECTOR

ORGANIZATIOANL STRUCTURE

Board of Directors

Chairman

Managing Director
 General Manager

Accounts Production Purchase Marketing Personnel Store

Officer Manager Manager Manager Manager Keeper

Assistant. Head Time Staffs

Accounts Supervisors Supervisor
Marketing Keeper
Staffs Manager

Production Workers Clerk

Staff

Workers

CHAPTER III GENERAL MANAGER

FUNCTIONAL DEPARTMENT ANANLYSIS

PRODUCTION DEPARTMENT
STRUCTURE OF PRODUCTION DEPARTMENT

PRODUCTION MANAGER

SPINNING MASTER
PROCESS FLOW CHART

Mixing & Blending

Blow Room

Combed Yarn

CARDING

Silver Lap Drawing

Ribbon lap Lap Former

Combing

Drawing 1

Drawing 2

Simplex

Reeling Spinning Winding

Bundling Double Packing

Barling Market
OPERATIONS
PRODUCTION

The head of the production department is mill manager; the planning and
control of production are done by the mill manager. He gives necessary instruction to spinning
master for doing the desired objectives. He gives necessary instruction to spinning master for
doing the desired objectives; the deputy spinning master also helps the master for his work.
These plans are implemented through the shift supervisor.

STRUCTURE OF PRODUCTION DEPARTMENT

Mill Manager

Spinning Master

Deputy Spinning Master

Shift Supervisor

Skilled Worker
CAPACITY & PRODUCTIVITY OF THE MILL

The production of QCSML started 13-02-1986. But the whole operation

was commenced by the end of the financial year 86-87. In 98-99 the QCSML couldn’t use the
whole plant capacity because of the absenteeism of workers and power failures.

PRODUCTION OF COTTON YARN IN THE MILL

The mill adopts the ‘production to stock’ method. In this method they produce goods according
to demand for the product. According to the demand of the product the production process will
vary. During the working condition the tem is maintained at 34 Degree C, otherwise the yarn will
be broken during the process. The quality controller the quality of goods, during production and
after production.
As per the requirement of QCSML, first of all tenders are invited from suppliers and purchase
order is given to the suppliers. The payment to the suppliers are done, 20% will be made within
30 days, balance within 3 months.

PRODUCTION PROCESS

Mixing

Blow Room

Carding
Draw Frames

Fly Frames

Ring Frame

Winding

Reeling

Doubling

Packing.
MIXING:
In this department cotton are graded according to various fiber properties like length, strength,
fineness, color etc. Properties vary with different varieties of cotton. The working of blending
different cotton together is done in the departments, where the different varieties are taken in
required proportions and arranged on the lattice of the blenders or bale plungers of the blow
room machinery. Sometimes useful wastes are also mixed.

COTTON MIXING
Cotton is a hygroscopic material, hence it easily adapts to the atmospheric air conditions. Air
temperature inside the mixing and blow room area should be more than 25 degree centigrade and
the relative humidity (RH %) should be around 45 to 60 %, because high moisture in the fibre
leads to poor cleaning and dryness in the fibre leads to fibre damages which ultimately reduces
the spin ability of cotton. Cotton is a natural fibre. The following properties vary very much
between bale (between fibres) fibre micronaire fibre length fibre strength fibre color fibre
maturity. Out of these, fibre micronaire, color, maturity and the origin of growth results in dye
absorption variation. Therefore it is a good practice to check the maturity, color and micronaire
of all the bales and to maintain the following to avoid dye pick up variation and barre in the
finished fabric.

BALE MANAGEMENT:

In a particular lotMicronaire range of the cotton bales used should be same for all the mixings of
a lot Micron ire average of the cotton bales used should be same for all the mixings of a lot
Range of color of cotton bales used should be same for all the mixings of a lot Average of color
of cotton bales used should be same for all the mixings of a lot Range of maturity coefficient of
cotton bales used should be same for all mixings of a lot.
Average of maturity coefficient of cotton bales used should be same for all mixings of a lot
Please note, in practice people do not consider maturity coefficient since Micronaire variation
and maturity variation are related to each other for a particular cotton.

If the cotton received is from different ginners, it is better to maintain the percentage of cotton
from different ginners through the lot, even though the type of cotton is same. It is not advisable
to mix the yarn made of out of two different shipments of same cotton.
For example, the first shipment of west-African cotton is in January and the second shipment is
in March, it is not advisable to mix the yarn made out of these two different shipments. If there is
no shade variation after dyeing, then it can be mixed.
According to me, stack mixing is the best way of doing the mixing compared to using automatic
bale openers which picks up the material from 40 to 70 bales depending on the length of the
machine and bale size, provided stack mixing is done perfectly. Improper stack mixing will lead
to BARRE or SHADE VARIATION problem. Stack mixing with Bale opener takes care of short
term blending and two mixers in series takes care of long term blending.

Tuft sizes can be as low as 10 grams and it is the best way of opening the material(nep creation
will be less, care has to be taken to reduce recycling in the inclined lattice)contaminations can be
removed before mixing is made The raw material gets acclimatized to the required temp and
R.H.%, since it is allowed to stay in the room for more than 24 hours and the fiber is opened , the
fibre gets conditioned well.
DISADVANTAGES:
 more labour is required
 more space is required
 mixing may not be 100% homogeneous( can be overcome by installing double
 mixers)

If automatic bale opening machine is used the bales should be arranged as follows let us assume
that there are five different micronaires and five different colors in the mixing, 50 bales are used
in the mixing. 5 to 10 groups should be made by grouping the bales in a mixing so that each
group will have average micronaire and average color as that of the overall mixing. The position
of a bale for micronaire and color should be fixed for the group and it should repeat in the same
order for all the groups
 It is always advisable to use a mixing with very low Micronaire range. Preferably.6 to
1.0. Because it is easy to optimize the process parameters in blow room and cards
drafting faults will be less dyed cloth appearance will be better because of uniform dye
pickup etc
 It is advisable to use single cotton in a mixing, provided the length, strength micronaire,
maturity coefficient and trash content of the cotton will be suitable for producing the
required counts. Automatic bale opener is a must if more than two cottons are used in the
mixing, to avoid BARRE or SHADE VARIATION problem.
 It is better to avoid using the following cottons with inseparable trash (very small size),
even though the trash % is less sticky cotton (with honey dew or sugar)cotton with low
maturity co-efficient
 Stickiness of cotton consists of two major causes. Honeydew from Whiteflies and aphids
and high level of natural plant sugars. The problems with the randomly distributed honey
dew contamination often results in costly production interruptions and requires
immediate action often as severe as discontinuing the use of contaminated cottons. An
effective way to control cotton stickiness in processing is to blend sticky and non-sticky
cotton. Sticky cotton percentage should be less than 25%.

BLOWROOM
Basic operations in the blow room:
 opening
 cleaning
 mixing or blending
 micro dust removal
 uniform feed to the carding machine
 Recycling the waste
Blow room installations consist of a sequence of different machines to carry out the above said
operations. Moreover Since the tuft size of cotton becomes smaller and smaller, the required
intensities of processing necessitates different machine configuration.

TECHNOLOGICAL POINTS IN BLOWROOM

 Opening in blow room means opening into small flocks. Technological operation of
opening means the volume of the flock is increased while the number of fibres remains
constant. i.e., the specific density of the material is reduced.
 The larger the dirt particle , the better they can be removed
 Since almost every blow room machine can shatter particles, as far as possible a lot of
impurities should be eliminated at the start of the process. Opening should be followed
immediately by cleaning, if possible in the same machine.
 The higher the degree of opening, the higher the degree of cleaning. A very high cleaning
effect is almost always purchased at the cost of a high fibre loss. Higher roller speeds
give a better cleaning effect but also more stress on the fibre.
 Cleaning is made more difficult if the impurities of dirty cotton are distributed through a
larger quantity of material by mixing with clean cotton.
 The cleaning efficiency is strongly dependent on the TRASH %. It is also affectedly the
size of the particle and stickiness of cotton. Therefore cleaning efficiency can be different
for different cottons with the same trash %.
 There is a new concept called cleaning resistance. Different cottons have different
cleaning resistance.
 If cotton is opened well in the opening process, cleaning becomes easier because opened
cotton has more surface area, therefore cleaning is more efficient
 If automatic bale opener is used, the tuft size should be as small as possible and the
machine stop time should be reduced to the minimum level possible
 If Manual Bale openers are used, the tuft size fed to the feed lattice should be as small as
possible
 Due to machine harvesting, cotton contains more and more impurities, which furthermore
are shattered by hard ginning. Therefore cleaning is always an important basic operation.
 In cleaning, it is necessary to release the adhesion of the impurities to the fibresand to
give hte particles an opportunity to separate from the stock. The former is achieved
mostly by picking of flocks; the latter is achieved by leading the flocks over a grid.
 Using inclined spiked lattice for opening cotton in the intial stages is always a better way
of opening the cotton with minimum damages. Of course the production is less with such
type of machines. But one should bear in mind that if material is recycled more in the
lattice, nets may increase.
 Traditional methods use more number of machines to open and clean natural fibres.
 Mechanical action on fibres causes some deterioration on yarn quality, particularly in
terms of neps. Moreover it is true that the staple length of cotton can be significantly
shortened.
 Intensive opening in the initial machines like Bale breaker and blending machines means
that shorter overall cleaning lines are adequate.
 In a beating operation, the flocks are subjected to a sudden strong blow. The inertia of the
impurities accelerated to a high speed, is substantially greater than that of the opened
flocks due to the low air resistance of the impurities. The latter are hurled against the grid
and because of their small size, pass between the grid bars into the waste box, while the
flocks continue around the periphery of the rotating beater.
 By using a much shorter machine sequence, fibres with better elastic properties and
improved spin ability can be produced.
 Air streams are often used in the latest machine sequence, to separate fibresfrom trash
particles by buoyancy differences rather than beating the material against a series of grid
bars.
 There are three types of feeding apparatus in the blowroom opening machines two feed
rollers( clamped)feed roller and a feed table a feed roller and pedals
 Two feed roller arrangements gives the best forwarding motion, but unfortunately results
in greatest clamping distance between the cylinders and the beatingelementfeed roller and
pedal arrangement gives secure clamping throughout the width and a small clamping
distance, which is very critical for an opening machine In a feed roller and table
arrangement, the clamping distance can be made very small.
 This gives intensive opening, but clamping over the whole width is poor, because the
roller presses only on the highest points of the web. Thin places in the web can be
dragged out of the web as a clump by the beaters Honeydew (sugar) or stickiness in
cotton affect the process very badly.Beacause of that production and quality is affected.
Particles stick to metal surfaces, and it gets aggravated with heat and pressure. These
deposits change the surface characteristics which directly affects the quality and running
behavior.
 There are chemicals which can be sprayed to split up the sugar drops to achieve better
distribution. But this system should use water solutions which are not recommended due
to various reasons. It is better to control the climate inside the department when sticky
cotton is used.
 Low temperature (around 22 degree celcius) and low humidity (45% RH). This requires
an expensive air conditioning set up.
 The easiest way to process sticky cotton is to mix with good cotton and to process
through two blending machines with 6 and 8 doublings and to install machines which will
segregate heavier particles by buoyancy differences.
 General factors which affect the degree of opening, cleaning and fibre loss are,
 Thickness of the feed web density of the feed webfibre coherencefibre alignment size of
the flocks in the feed (flock size may be same but density is different)the type of opening
device speed of the opening device degree of penetration type of feed (loose or
clamped)distance between feed and opening device
 Type of opening device
 Type of clothing
 Point density of clothing
 Arrangement of pins, needles, teeth
 Speeds of the opening devices
 Throughput speed of material
 Type of grid bars
 Area of the grid surface
 Grid settings
  Airflow through the grid
 Condition of pre-opening
 Quantity of material processed,
 Position of the machine in the machine sequence
 Feeding quantity variation to the beater
 Ambient r.h.%
 ambient temperature

BLOW ROOM:
The main purpose of blow room is opening, closing and cleaning or cotton in this department
the cotton is fed at one end and the output is achieved at a sketcher, which is the last machine in
the sequence of machinery of the blow room in the form of a lap. A lap is a sheet of cotton fleece
rolled around an iron rod inserted in the lap spindle. When the full lap is removed from the full
sketcher, the spindle is pulled out and the lap remains around the iron rod. The lumps of cotton
are gradually broken down to smaller size by the process of trembling, beating action etc. of the
spiked roller, lattice and beaters of the blow room machinery.

Blow room is one of the most important parts of textile spinning sector. It is consists of a number
of machines which are sued in succession to open and clean the cotton fibre according to the
required amount of degree. In blow room section, normally 40-70% trash is removed.
 Blow room section in spinning
BLOW ROOM SECTION:
It is that kinds of section where the supplied compressed bales are opened, cleaned and mixing or
blending for making uniform lap of definite length. The range of blow room cleaning efficiency
is 60-65%. It should be noted here that, blow room is the first section of spinning line for
producing cotton yarn.

BASIC OPERATION IN BLOW ROOM:

The below operation has don main blow room section of a spinning line:
 Opening,
 Cleaning,
 Mixing or blending,
 Lap forming.
All the above operations have explained in the following:
1. Opening:
Here, the compressed bales of fibres are opened for making the cotton tuft in a small size (as
much as possible).

2. Cleaning:
This operation is used to remove dust, dirt, broken leafs, broken seeds, stalks and other foreign
materials from the fibres.

3. Mixing or blending:
Mixing or blending process has performed for producing higher quality yarn by reducing
production costing which is only possible by mixing different grade of fibres.

4. Lap forming:
 This operation has done due to the below reasons:
 It is done to transfer the opened and cleaned fibres into a sheet form of specific width and
uniform unit length which is termed as lap.
  It is also used to roll the lap of predetermined length into a cylindrical shape around a lap
pin.
 It is also used to transfer the lap from the lap pin int a rod to suitable handle and feed it to
subsequent processing carding machine.
CARDING
The blow room lap, which is still in the form of small tuff in the lapis brought to this
department and fed to the carding machines. These are opened to the stage of single fibre on the
card by means of carding action between pointed wires mounted in the surface of licker in,
cylinder and plates. The opened fibres are collected by the doffer comb in the formals of a web.
This web is then passed through the trumpet to give to the shape of a rope and coiled inside a can
by means of a coiler.

Carding
Carding is one of the most important operations in the spinning process as it directly determines
the final features of the yarn, above all as far as the content of neps and husks are concerned.
There are many objectives of the carding process and these can be summarised as:
 Opening the tufts into individual fibres;
 Eliminating all the impurities contained in the fibre that were not eliminated in the
previous cleaning operations;
 Selecting the fibres on the basis of length, removing the shortest ones;
 Removal of neps;
 Parallelizing and stretching of the fibre;
 Transformation of the lap into a sliver, therefore into a regular mass of untwisted fibre.

The carding operation is carried out by the card, a machine that in practice is a system of rotating
organs, mobile and fixed flats, covered with steel spikes that go by the name of wiring. It is a
good idea to know what the wiring and its functions are before going onto a description of the
card.

Wiring and Clothing

 There are different types of cylinder wiring, in particular:
  rigid wiring, for rotating parts;
 elastic clothing, for mobile flats;
 Clothing for fixed flats.
The most common on the machine are the wiring type. They are made up of a steel wire with
sharp cutting teeth; the saw tooth like edge of the wiring is hardened in order to better resist wear
caused by the abrasive action of the fibers. The base of the wiring is thicker than the toothed
parts, both to guarantee support to keep the teeth in a vertical position, as well as to prevent
lateral contact between the teeth and to permit the necessary momentary penetration of fibre into
the wiring.

The sizes of the teeth vary notably and depend on how compact the material is, on the quantity
and on the fineness of the fibre. The parameters which permit one type of wiring to be
distinguished from another are:
Concentration, meaning the number of teeth in a square inch of the wiring (for the various
devices of the card the concentration is different and is strictly linked to the type of fibre used;
for fine fibre, for example, wiring with a high concentration is used);

The height of the teeth, which can vary according to the wired element;
 The angle between the teeth and the base in a longitudinal sense.
 It is a known fact that a wired element moves in:
 a positive way when it moves in the same direction as the inclination of the teeth;
 a negative way when it moves in the opposite direction to the inclination of the teeth
 The fibrous material is found between the two wired elements which, by moving, act on
the fibre in an alternate manner: first they trap it then they remove it. Depending on the
layout of the teeth, the direction travelled and the speed of the devices, two conditions are
possible, called:
 Carding position which is obtained when the teeth of the wired elements are inclined in
an opposite direction and their movement occurs with a certain speed and in a direction
that permits reciprocal grasp of the fibre and then the disentangling of the neps and
elimination of trash and dust.
  Position of cleaning or brushing, which is obtained, on the other hand, when the devices
have converging teeth and their movement occurs with such a speed and in such a
direction to permit the passing of fibre from one organ to another.

DRAW FRAMES:

The card silver lacks on regulating the fibres and the fibres are also in a crisis condition. In
order to spin and even and regular yarn the silver for better control of the fibres during drafting
in succeeding process and also for obtaining better strength of yarn spinning. The evenness of
silver and parallelization of fibre is achieved at the draw frame when 6-8 more silver are again
fed to another draw frame. The finished draw frames are transferred to fly frame.
DRAW FRAME
Drawing is the operation by which slivers are blended, doubled and leveled. In spinning the term
is only applied to the process at a draw frame. In drawing slivers are elongated when passing
through a group of pair rollers, each pair is moving faster than previous one. This permits
combing, drawing and elongating of several slivers to make them strong and uniform.In most
modern worsted drawing sets there are 3 passages of pin drafting and roving process.
OBJECTS OF DRAWING

 To straighten the crimped, curled and hooked fibers.

 To make the fiber parallel to their neighbors.
 To improve uniformity of fibers by drafting and doubling.
 To reduce weight per length unit of sliver.
 To remove dust from slivers.
 To blend raw material of same hank perfectly.
IMPORTANCE OR NECESSITY OF DRAW FRAME IN YARN PRODUCTION
 To parallelization of fiber and blending the carded sliver, draw frame is needed.
 In carded sliver, fibers are present in hook form i.e. trailing hooks and leading hooks. To
parallel these hooks raw frame is used.
 Majority of the fiber hooks in a carded sliver are trailing hooks while leading hooks are
comparatively less.
 Trailing hooks are also known as major hooks, while leading hooks are known as minor
hooks.
  What should do for better performance of drawframe:
 Always keep a watch on humidity and temperature as it affects the working.
 Keep a watch on stop motions and ensure that no singles or doubles are fed to drafting.
Ensure machine stopping before a broken sliver entering drafting zone.
 Verify the trumpets size as per the hank, and ensure in good condition.
 Keep a watch on the surface of the top rollers and pressure on top roller

FLY FRAMES:

The silver from draw frame is fed to fly frames. The silver is drafted and reduced
in diameter and slightly twisted and wound on the bobbin by means of the flyer.
SPEED FRAME:
Simplex is an intermediate process in which fibers are converted into low twist lea called roving.
The sliver which is taken from draw frame is thicker so it is not suitable for manufacturing of
yarn. Its purpose is to prepare input package for next process. This package is to prepare on a
small compact package called bobbins. Roving machine is complicated, liable to fault, causes
defect adds to the production costs and deliver the product. In this winding operation that makes
us roving frame complex. There are two main basic reasons for using roving frame.

Speed frame
 Necessity of Speed Frame:
  The first reason is related to the required draft. Sliver is a thick, untwisted strand that
tends to be hairy and to create fly. The draft needed to convert this to a yarn is in the
region of 300-500.
 Thedrafting arrangements of ring spinning machines, in their current forms, are not
capable of processing this strand in a single drafting operation to create a yarn of short-
staple fibers that meets all the normal demands on such yarns.
 The fine , twisted roving is significantly better suited to this purpose.
 The second reason is that draw frame cans represent the worst conceivable mode of
transport and presentation of feed material to the ring spinning frame.
OBJECTS/ FUNCTIONS OF SPEED FRAME
 Attenuation of drawn sliver to form roving of required count by drafting.
 Insert small amount of twist to give required strength of roving.
 Wind the twisted roving on to the bobbin.
 Build the roving in bobbin such a form which will facilitate handling, withdrawing &
transfer to the next process.

OPERATIONS INVOLVED IN SIMPLEX MACHINE:

 Cree ling
 Drafting
 Twisting
 Winding
 Building
 Doffing
CREELING:
To feed the sliver by the help of several rows of driver rollers to the machine.
 Creel draft
 Creel Stop motion
 Block creeling
DRAFTING:
To reduce the wt/unit length of sliver to make it suitable for ring spinning system.
 TWISTING:
To insert small amount of twist to give required strength of roving.

WINDING :
To win the twisted roving on to bobbin

BUILDING:
To build the roving in bobbin such a form which will facilitate handling, withdrawing & transfer
to the next process.
DOFFING:
To replace an empty bobbin at the place of full roving bobbin.

RING FRAME:
The roving wound on the bobbins at the fly frame is fed to the ring frame creel. The
bobbin is drafted to the fineness to the required and is twisted as it is delivered from the nip of
the front roller pairs. It is wound on the bobbin or spindle through the traveler which rotates
along the flange of the ring. The difference in the speed of the spindle and the traveler results in
the winding of the yarn in the bobbins.
INTRODUCTION
The ring spinning machine was invented in the year 1828 by the American Thorp. In 1830, another Amer
contributed the traveller rotating on the ring. In more than 150 years that have passed since that time, the m
experienced considerable modification in detail, but the basic concept has remained unchanged. Fig. 1 shows a t
frame.
Fig.1 : Typical view of a Ring Frame

The long central section of the machine, on which production is actually carried out, consists primarily of lo
members in the form of spindle rails and drafting rollers extending over the complete machine length.
These longitudinal members are secured to intermediate sections arranged at short intervals along the machine l
sections also serve as supports for the creel .
The ring spinning machine has been the most widely used form of spinning and it will continue for some more tim
it has unique advantage over new spinning technologies:

 It is universally applicable, most of the textile fibres can be spun to required fineness.
 The yarn spun from this machine demonstrate excellent quality features like uniform structure a
strength.
 It is easy to operate as compared to other spinning machines.
 The “know-how” for operation of the machine is well established.
 It is flexible as regard to quantities in terms of blend and lot sizes.

For these reasons, new spinning processes (with the exception of rotor spinning) have difficulty in gaining w
acceptance.
Disadvantages associated with ring spinning are:

 More process stages. Roving stage exists as an extra process compared to the other systems.
 Yarn breakages are more frequent as a result of ring traveller friction and yarn to air drag forces. Interr
broken ends and piecing up problems exist because of the yarn breakages.
 The high speed of the traveller damages the fibers.
 The capacity of the cops is limited.
 Energy cost is very high.
 Low production rate.

In long term, the ring frame can survive in longer term only if further success is achieved in automation of the rin
process. Also, spinning costs must be markedly reduced since this machine carries significant cost factor in spinni
Operation of the Ring frame
Task of the ring spinning

  Attenuate the roving until the required fineness is achieved

  To impart strength to fiber strand by twisting it
  To wind up the resulting yarn in a form suitable for storage, transportation and further processing

Principles of operation
Fig. 2 shows the operating parts of the ring frame and the principle of operation is explained below:
Fig.2 : Operating Parts of Ring Frame

 The roving bobbins (1) are creeled (A) in appropriate holders (3). Guide rails (4) lead the rovings (2)

drafting arrangement (5) which attenuates them to the final required count.
 The drafting arrangement (B) is inclined at an angle of about 45 – 600. It is one of the most im
 assemblies on the machine since it has considerable influence on irregularities present in the yarn.
 After the drafting arrangement, the machine have twisting and winding zone (C).
 Upon leaving the front rollers, the emerging fine fiber strand (6) receives the twist needed to give it s
 This twist is generated by the spindle, which rotates at high speed. Each revolution of the spindle imp
turn of twist to the fiber strand. Spinning of the yarn is thus complete.
 In order to wind up the twisted yarn to bobbin mounted on Spindle( 8) , a traveller (9) is required to co

with the spindle. The traveller moves on guide provided on the ring (10) encircling the spindle.
 The traveller has no direct drive; instead, it is carried along by the yarn it is threaded with. The spee

traveller is lower than that of the spindle owing to significant friction generated between the traveller and
 This difference in speed enables winding of the yarn to bobbin.
 Winding of the yarn on to the bobbin is done by raising and lowering the ring rail. The traverse strok
 ring rail is less than that of the bobbin height. The ring rail must therefore be raised by small amount af
layer of coils.

Cross-section of the machine

Fig. 3 shows the cross-section of a typical ring spinning machine. The ring frames are two sided machines with th
positions located on both sides of the machine. Each spindle is a spinning position. The spindle rail houses the sp
creel housing the feed roving bobbins are arranged in two rows on each side of the machine. The drafting arra
carried on the roller beams. Each intermediate section stands on two feet adjustable in height by means of screw
permitting easy leveling of the machine.
Fig.3 : Cross-section through the machine

In modern machines, an auto-doffer is also provided. Including the auto-doffer, the width of the machine varies f
1000 mm (up to 1400 mm when the doffer arm is swung out). Today, the machine length can reach 50 m. Spin
usually lie between 70 and 90 mm.

Sources :
WINDING:

The yarn spin at the ring frame and double yarn from doubling frame is wound on the
bobbin; this is a very small package. The cheese produced at the winding machine is either fed to
double when yarn is to be doubled or sent to the packing department. The main function of
winding machine is changing the yarn useful to power looms.

Winding is the process of transferring yarn or thread from one type of package to another to
facilitate subsequent processing. The re-handling of yarn is an integral part of the fiber and
textile industries. Not only must the package and the yarn itself be suitable for processing on the
next machine in the production process, but also other factors such as packing cases, pressure
due to winding tension, etc., must be considered. Basically, there are two types of winding
machines: precision winders and drum winders. Precision widers, used primarily for filament
yarn, have a traverse driven by acam that is synchronized with the spindle and produce packages
with a diamond-patterned wind. Drum winders are used principally for spun yarns; the package
is driven by frictional contact between the surface of the package and the drum.
 Yarn Winding Package
Types of Winding:
 Precision Winding
 Non Precision Winding

PRECISION WINDING

By precision winding successive coils of yarn are laid close together in a parallel or near parallel
manner. By this process it is possible to produce very dense package with maximum amount of
yarn stored in a given volume.

FEATURES OF PRECISION WINDING

 Package are wound with a reciprocating traverse

 Patterning and rubbing causes damage of packages
  Package contains more yarn
 Package is less stable
 The package is hard and compact
 The package is dense
 Rate of unwinding of package is low and the process of unwinding is hard
 The unwound coil is arranged in a parallel or near parallel manner
NON PRECISION WINDING
By this type of winding package is formed by a single thread which is laid on the package at
appreciable helix angle so that the layers cross one another and give stability to the package. The
packages formed by this type of winding are less dense but is more stable.

FEATURES OF NON PRECISION WINDING

 Only one coil is used to make this packages

 Cross winding technique is used
 The package density is low
 Minimum number of yarn is wound
 The package formed is soft and less compact
 The stability is high
 Flanges are not required
 The rate of unwinding is high and the process is easy
 The packages formed have low density

REELING :
The yarn is to be supplied to in the form of hanks. The bank yarn is produced in the reeling
machine. The hanks are wound from bobbins.
 Reeling
 Reeling or making of hanks
 Watch video here
  The Reeling is a procedure which converts yarn into commerically portable form. The
outcome of reeling is called hanks or skeins. It is normally done after twisting/Winding to
wrap yarn carefully for processing in hank form and unwinding it later. The reeled yarn is
carefully tie-banded to control fibres during handling, scouring, Dyeing and unwinding.

These machines are used to convert the yarn in hank form .The hanks produced as per the quality
of yarn ,further processing facility such as dyeing, drying ,hank to cone winding etc.
Mail characteristics of hanks are
o Hank diameter
 Hank weight
 Hank traverse
 Crossing angle such as diamond.
 Formation of hank such as rectangular ,trapezoidal, cop built or lea hanks.

MAIN FEATURES OF A REELING MACHINE

1.SWIFT AND ITS CIRCUMFERENCE SETTING
 Hanks of various sizes such as weight ,circumference, width and make up are used
depending upon the substrate quality (cotton, viscose, silk, wool, acrylic etc ), physical
and aesthetic features of the yarn, end use ,further processing machinery set up such as
mercerizing, dyeing ,hydro extraction , drying and hank to cone winding. Generally 54
“(1370 mm) to 90 “(2286 mm) circumference hanks are used
  In most of the cases the swift of the machine is adjustable to accommodate the different
circumferences or swift sets are available for particular ranges such as in crune luke
machines 3 different sets are available
 swift circumferences:
1. Size 1 1.350 – 1.524 mm
2. Size 2 1.500 – 1.905 mm

• Size 3 1.800 – 2.337 mm

2.Yarn guide system

The yarn laying system has thread guides which are controlled electronically for changing the
hank features , type of hanks and to select different crossing angles.
3.Hank doffing system
The doffing could be manual or automatic after the completion of hanks.

4. Hank parameter setting or type of hank

Different types of hank formation or lay out can be made depending upon the type of yarn and
further processing machinery such as,
 rectangular
 trapezoidal
 cop-built

lea-hanks
A trapezoidal or tapered end hank
5. Hank positions
It is the number of hanks which can be made on the full machine ,with a particular set of
parameters. The hank positions are less when the hank width or traverse is more.
6.Leasing system

Leasing is tying the hanks at various places(1-6) with stronger threads or yarns by inserting the
thread throughout the traverse at selected points. Generally leasing in the hanks is done manually
to keep them intact in the further processing such as mercerizing, dyeing, hydro extraction,
drying and to facilitate efficient and trouble free hank to cone winding. There are different
systems for leasing as shown below double eight one and a half eight single eight

in crune luke machine automatic leasing system CLT is available.

7.Length measuring system
Modern reeling machines are equipped with length measuring devices to keep the yarn length
constant from one hank to another, to get a uniform hank weight for better results in further
processing such as dyeing and to make uniform size packages in hank to cone winding.
8.Hank width setting or traverse
The traverse or width of hanks is important for a particular hank weight to get uniform results in
further processing; generally a range from 80 mm to 380 mm is available from the different
manufacturers.
9. Yarn tension control system
The yarn tension from the feed package is regulated to get the uniform reeling results and precise
winding in all the hanks. Modern reeling machines are equipped with automatic yarn tension
control system
10. Reeling speed and maximum obtainable hank weight.
The reeling speed depends upon the number of factors such as type of yarn and required hank
weight and circumference. The machines are available with a maximum winding speed up to
1500 m/min. Hank weight is also decided by the set up of further processing machinery as well
as the type of yarn processed . The maximum hank weight as per the different manufacturers is
up to 2.5 kg . For mercerized cotton yarn a weight of 1-1.5 kg is generally adopted.
11. Crossing angle and diamond

It is distinct characteristic of hank for uniform dyeing and efficient hank to cone operations. It
could be selected in a step less manner or diamond formation as shown below from 1:1 to 1:6.
12. Splicing and yarn clearing system
To avoid the manual knotting in case of yarn breakage and yarn faults to be carried forward in
further processing.
DOUBLING:

In the doubling process two single yarns are twisted together to give a Double yarn.
This increase the strength of the yarn. If two single yarn of 10s count are doubled,
Resulted yarn will be 2/10s count.

PACKING :

The yarn is sold in hank form or as cones. Hanks are packed as bundles. One bundle
contains 4.5Kg of 20 or more hanks. Cones are packed in bags. One bag contains 40 cones of
which one cone weight 1.25Kg. During the time of production and after the production, the
quality is checked by the quality controller
Grading of the product

In QCSML grade of the cotton are measured in count and they are as follows. 20’s,40’s,
50’s, 60’s, 80’s 120 count is the best count but in this mill 40 count is used. This mill produces
mainly 2 types of cotton yarn namely, Cons and Hanks. Now a day it also produces polyester
yarn. The working condition is always maintained at 34degree C tem else the yarn will be broken
during the procedure

WASTE
The production process creator 2 types of waste. They are usable, and saleable .usable wastes are
again sending to the production process of mixing and blowing. Saleable wastes are sold and
scrap value is obtained.

SOURCE OF PURCHASE

The purchase is made from the cotton producing federators. But now the mill
management is going for private suppliers and individual agents. Because their suppliers found
to be high cost, low quality etc.
SUPPLIERS OF RAW MATERIAL

 Private parties.
 Vijay Lekshmi Enterprises- Kundara
 Sreenivas- Kundara
 L. Davarajan and co-Coimbatore.
 Arakal cotton co-Thrichur
 Chaithanya cotton concern- Kundara
 P.K. Sumbramanyam- Coimbatore

QUALITY CONTROLL DEPARTMENT

This department refers to the systematic control of various factors that

affect the quality of the end product. The quality of the end products depends on the quality of
the raw materials used, manufacturing equipments the degree of skill and proficiency of the
workers etc. During the time of production and after the production the quality controller
checked the quality of the product. It will help to eliminate the weaving mistakes. Now a days
the mill started computer testing labs for checking the quality of yarn at each machine. Then they
can produce good quality products.

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.
CHAPTER III
FUNCTIONAL DEPARTMENT ANANLYSIS

PRODUCTION DEPARTMENT
STRUCTURE OF PRODUCTION DEPARTMENT

PRODUCTION MANAGER

SPINNING MASTER

ASSISTANT ASSISTANT
PRODUCTION MAINTENANCE
MANAGER MANAGER

PROCESS FLOW CHART

SUPERVISOR

Mixing & Blending

WORKERS

Blow Room

Combed Yarn

CARDING

Silver Lap Drawing

Ribbon lap Lap Former

OPERATIONS
PRODUCTION

The head of the production department is mill manager; the planning and
control of production are done by the mill manager. He gives necessary instruction to spinning
master for doing the desired objectives. He gives necessary instruction to spinning master for
doing the desired objectives; the deputy spinning master also helps the master for his work.
These plans are implemented through the shift supervisor.

STRUCTURE OF PRODUCTION DEPARTMENT

Mill Manager

Spinning Master

Deputy Spinning Master

Shift Supervisor

Skilled Worker
CAPACITY & PRODUCTIVITY OF THE MILL

The production of QCSML started 13-02-1986. But the whole operation

was commenced by the end of the financial year 86-87. In 98-99 the QCSML couldn’t use the
whole plant capacity because of the absenteeism of workers and power failures.

PRODUCTION OF COTTON YARN IN THE MILL

The mill adopts the ‘production to stock’ method. In this method they produce goods according
to demand for the product. According to the demand of the product the production process will
vary. During the working condition the tem is maintained at 34 Degree C, otherwise the yarn will
be broken during the process. The quality controller the quality of goods, during production and
after production.
As per the requirement of QCSML, first of all tenders are invited from suppliers and purchase
order is given to the suppliers. The payment to the suppliers are done, 20% will be made within
30 days, balance within 3 months.

SOURCE OF PURCHASE

The purchase is made from the cotton producing federators. But now the mill
management is going for private suppliers and individual agents. Because their suppliers found
to be high cost, low quality etc.
SUPPLIERS OF RAW MATERIAL

 Private parties.
 Vijay Lekshmi Enterprises- Kundara
 Sreenivas- Kundara
 L. Davarajan and co-Coimbatore.
 Arakal cotton co-Thrichur
 Chaithanya cotton concern- Kundara
  P.K. Sumbramanyam- Coimbatore

QUALITY CONTROLL DEPARTMENT

This department refers to the systematic control of various factors that

affect the quality of the end product. The quality of the end products depends on the quality of
the raw materials used, manufacturing equipments the degree of skill and proficiency of the
workers etc. During the time of production and after the production the quality controller
checked the quality of the product. It will help to eliminate the weaving mistakes. Now a days
the mill started computer testing labs for checking the quality of yarn at each machine. Then they
can produce good quality products.

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.

PERSONNEL DEPARTMENT

DEPARTMENT STRUCTURE
 PERSONNEL MANAGER

CANTEEN TIME OFFICE SECURITY GUARD

 Personnel
Type of works No required No available
manager heads
the department.
Under him there
is a head time

Officers Required Available Remarks

General Manager 1 1

Factory Manager 1 1

Personnel Manager 1 1

Accounts Manager 1 1

Deputy Spinning manager 1

Asst Spinning manager 1 1

Asst Engineer 1 1

keeper and a security inspector. PF, ESI and canteen sections are also working under this
department.

The Personnel manager is also in charge of welfare officer as there is no separate post in the
mill. Personnel department has the duty to look after the areas including recruitment, selection,
placement, training, promotion, long term agreements, administrating mills quarters, disciplinary
actions etc.

The factory works 7 days in a week, 24 hrs a day with three shifts.

The shift timing: 7.30 AM to 3.30 PM

: 3.30 PM to 11 .30 PM

: 11.30 PM to 7.30 AM
 Supervisors 13 6
Mill workers 363 212
Casual labors 170 170

STAFF AND MILL WORKERS

PERMANENT OFFICERS

The mill has 202 workers on roll.

Clerical staff on roll was:-20

Supervisors :-6

The actual requirement of the mill is 363 permanent workers for the full production. The deficit of
the workers is managed by appointing casual labors on daily wages. Now the company has almost
170 casual labors on roll.

RECRUITMENT

The mill is being a sick industry; the company has banned direct recruitment, and
appointment of the officers. If the employees are divided into categories A, B, C & D. A & B are
managerial categories since 1992, there is ban on direct recruitment, and C & D are workers and
staff categories. The recruitment in these categories is done through employment exchanges.

The retirement age is 58 and if the workers are appointed 1970 the age is 60 years.

SELECTION

After recruitment, selection is done by ascertaining the qualifications of the candidate

with job requirements. The selection is conducted on the basis of

1. Test
2. Interview
3. Medical examination
 4. Appointment

After selection management will issue a memo, which is sent to the concerned candidate
indicating his/her selection. After this, they have to undergo apprentice ship or probation to a
certain period. The stipend during this period will also be specified.

PLACEMENT

Placement is assigning appropriate job to candidates in the organization. After joining the
candidate must fill a bio-data from and an attestation from in his/her own handwriting? The
candidate should also submit a conduct certificate.

The time keeper will collect the required data relating to the person on the date of joining and keep it
on the service record of the person.

INDUCTION

After placement, the employee is given an induction by which he or she is introduced to the
co-workers, supervisor and exposed to process of production pattern, discipline, standing orders etc
of the mills.

Mill does not have a systematic implementation of induction program. The

personnel manager gives necessary instructions and guidelines regarding the work. After this the
newly appointed persons are guided by the head of the section.

PROBATION

After placement the employees are given certain period of probation. Here the probation period is 8
months for workers and one year for general staff. Only after the successful completion of the
probation, the employees are made permanent. If the performance is not good the probation will be
extended again. If the employee satisfactory completes probation he will be confirmed in that
particular post.

TRAINING AND DEVELOPMENT

 Training and development becomes important as far as the growth of the company is
concerned. As the mill does not have a separate training department, this function is performed by
personnel and production departments.

Training needs are assessed by consulting with various departments. The departments
which need trained labor report it to the personal department and makes necessary arrangements for
training programmer.

METHODS OF TRAINING

The workers are given only on the job training. The NTC staffs are sent to the NTC
staff training college, Coimbatore for training. The various training programme have been given to
managerial staff by different agencies.

PROMOTION AND TRANSFER

PROMOTION

The mill had followed the SITRA standard of promotion of employees which is specified
in the memorandum of settlement. The matters related to the service conditions of the workmen of
the textile industry in TAMILNADU as a whole was taken up by the Industrial Relations Committee
(IRC) for Textiles, constituted by the Govt. of TAMILNADU and a general industry wide settlement
under section 12(3) of the ID Act. This refers to an IRC settlement between employees and workmen
represented by the union of various textile mills in TAMILNADU.

As provided in the IRC settlement dated 1-12-1994, unit level discussions were
reached. As per the settlement the principle to be followed in case of promotion is merit-aim-
seniority. The promotion of management staff is done at corporate level. It is the supervisor
immediate to the workers who certify that a worker is eligible for promotion.
 The workmen becoming surplus in any category or department on account of
implementation of settlement shall be transferred from one category to another category or
department, while doing so the person shall be treated the junior most workmen in that category.

Line of promotion of workers

1. Blowing 2.CARDING

HOPE FEEDER CARD TENTEE

SECUTHEE TENTEE OILEE CUM JOHBEE

JOBBER CUM FITTER

ASST. FITTEE
3. DRAWING

DOFFING BOY

C LEANINIG GANG

BOBBIN
4. SIMPLEX 5.SPINNING
LARRIER
BACK TENTEE

DRAWING DOFFING
TEENTEE BOY
SIMPLEX DOFFING
TEENTEE CARIEE

OLIER SPINNIND
DOUBLEE
ASST. FITTEE RESENC
PIECER
 JOBEE OLICE CUM
TYPESTICHEE

DUFFING
JOBBEE
LINE JOBEE

6. POWER HOUSE 7.WORK SHOP

JUNIOR
ELECTRICTION HELPER

SENIOR ASST FITTEE

ELECTRION
SWITCH BOARD
FITTEE
OPERATOR

ASST. CHARGE
MAISTRY
MAN
CHARGE MAN

8. SECURITY GUARD 9.WINDING

SECURITY PACKEE
GUARD
WINDEE
HEAD SECURITY

OLIEE

ASST. FITTEE
9. CLEANING GANG

CLEANING GANG

CLEANING ASST. ROLLEE

HANG LEADER COVERER
ASST. FITTEE ROLLER
COVERER

FITTEE

10. REELING

REELING

YARN CARRIER SWEEPER

REELEE

MAISTRY

TRANSFER
 The management reserves the right to transfer employees from one shift to another according
to emergencies of work at its complete discretion. Inter departmental transfer is done to both workers
and clerical staff as per changes in count pattern, product mix, break down of machine idling of
machinery in order to adjust surplus workers. Any person in any of the mills which comes under the
Bangalore subsidiary wants to join in any of its other mills must give an application. If he agrees
with the terms and conditions of that mill, he is considered as the junior most of that mill. For the
unit staff transfer is not applicable. In normal circumstances no staff member will be transferred if he
has 3 or less years of service from his due date of retirement.

WAGE AND SALARY ADMINISTRATION

The personnel department effects prompts and correct payment of wage / salary every
month. The workers are paid their wages on the 7th of every subsequent month, while the mill staff
and NTC staff are paid their salary on 30th every month.

CALCULATION OF NET PAY

Net pay is calculated as:-

Net pay = (basic pay +

Increment +
DA +
H.R.A +
Other earnings)

Grows pay:

Less: (PF+ESI +others)

: = Net pay

A worker should have worked 26 days in a month can claim his whole month salary. For days not
worked, a reduction in salary will be effected. Basic pay, DA, H.R.A, are taken into account for
reduction.
WORKING HOURS

Adult workers are not permitted to work more than 9 hours in a day and 48 hours in a
week. Since there is absenteeism in the mill, workers are sometimes asked to work overtime. The
wage given would be the rate of twice his ordinary salary or rate of salary.

HOLIDAYS

The workers are not allowed to work in the unit on the first day of week unless he has or
will have a holiday or one of the three days immediately before or after the day.

INTTERVAL FOR REST

The period of work in the factory is fixed that no period shall exceed before he has an
interval for the rest of at least ½ hour.

PROHIBITION OF EMPLOYMENT

No child who has not attained or completed his fourteen years is allowed to work in
the unit.

CANTEEN

The canteen provides employees with good food in a subsidized rate. The canteen is
managed by a co operative society. Registered as such, society may include in the charges to the
made food stuffs served as up to 5% on its working capital employed in the running of the canteen.
The charge per portion of the food stuff, beverage and any other item served in the canteen shall be
conspicuously displayed in the canteen.

REST HOUSE

A rest house is in the company for the night shifters for their relaxation.

SPORTS AND RECREATION CLUB

This is for the relaxation of the workers. There are annual sports meet conducted in every
year. Under this mill there is a small library and reading room which provides various news papers
and magazines.
ALLOWANCES

National Textile Corporation provides allowances to the officers of the mill. Vehicle
allowance is also provided.

The mill provides quarters for both officers and workers. There is 58 quarters and for
those officers who do not avail this facility is authorized to get HRA.

BONUS

Bonus is given to workers at the time when company is in profit. Those workers who earn
salary up to Rs.10000/- is eligible to get bonus.

E.S.I

Free consultation and medicine is being provided to the workers by ESI.

PROVIDENT FUND

The corporations maintain and contribute to PF called Employees State Insurance PF in respect of its
employees other than those whose service are placed at the disposal of the corporation by the Central
or State Govt.

CONTRIBUTORY PF

For this type of PF, the percentage of salary is compulsory deducted from the workers
salary and the same percentage of amount is deposited by the management also. Presently PF
pension is given from percentage of amount contributed by the management. 10% contribution is
made by the management out of which 8.33% is given to pension fund.

WELFARE FUND

A welfare fund is established and maintained by the workers. There is a worker’s

committee for maintaining this fund. The committee decides the percentage of contribution. One
percentage contribution is made by the management. The amount is invested in a bank and at the
time of retirement, the employee is provided with that lump sum amount.

GRATUITY FUND
 Gratuity shall be payable to an employee who has rendered continues service for not less
than five years. The gratuity application must produced by the employee before thirty days of the
date of scope of retirement gratuity calculated in the way that for one year service 15 days salary is
given.

WORKERS COMMITTEE

A committee is constituted consisting of General Manager, Factory Manager, Personnel

Manager, Finance Manager, Three representatives of workmen to be decided by CEO/ General
Manager in consultation with the trade unions concerned in any manner as per the local conditions in
the mill, The chairman of the joint management council of the mill.

FUNCTIONS OF THE COMMITTEE

1. Production programme
2. Utilization
3. Efficiency
4. Productivity
5. Quality of products
6. Cost reduction
7. Improving profitability
8. Purchase
9. Sales including disposal

PARTICIPATION IN MANAGEMENT

The management has good relationship with the unions-various union functions as a term
in care of major matters. They understand the problems faced by the management and trying to
adjust with the conditions of the mills.

The majority of the unions are of the opinion that the management is not willing to consider the
problems and hazards faced by the workers.
They blame the management for its efficiency in dealing with the day to day affairs of the
employees.

GRIEVANCE HANDLING PROCEDURE

THE CONTIGENCY PLAN

1. WATCH ON LABOUR SITUATION

The shift supervisors, Asst. Spinning masteries and spinning masteries will keep a close
watch about the labor and have their own arrangements and sources to get inform on day today
development of labor situation. Impute inform will be directly and confidently passed on to the GM
by the quickest possible means. Labor welfare office will also collect information’s by conducting
union representatives and pass on the relevant information confidently to the GM. Once and above
this the GM will also find sources to collect information directly to keep him abreacts of the
developments in the mills
GM will convene meetings of the officers and supervisory staff members at regular inlivals
to discuss the labor situation.

2. PROMPT ARDRESSIAL OF THE GRIEVANCES OF LABOR

The probable grievances and demands of the employees are grouped for the convenient
handling of re dressed steps.

TRADE UNION

Trade union in the company is working very efficiently and in a very healthy manner. The
management able to maintain a good relationship with the members of the trade union. Presently
there are 3 trade unions including

 INTUC
 AITUC
 CITU
Though there are some other unions they are not accepted but the management only the members of
3 unions are allowed to be presenting representatives while meeting are conducted.

The mil has not faced any serious strikes or lock out for the past years.

TIME OFFICE DEPARTMENT

Personnel department controls another department called time office department. This
department maintains the entering and living time of workers.

As said earlier the mill is now working under 3 shifts, 24x7 and thus it is a tedium
work maintaining the record of around 393 workers. There for the time office department is having a
strenuous job of keeping and maintaining all the relevant records of hours of work of each
individual.

All the workers are provided with attendance card. This would be given at the
time of joining. The color of each card varies with shift and department. The worker has to give his
bin card to time officer before starting the shift. The worker will get back a card when he leaves the
factory.

Head time keeper is in charge of time office. The time keeper after collecting
the bin card of the workers, calculate the shortage of laborers and allot over time. There are senior
assistants and clerks to help the head time keeper.

FUNCTIONS OF TIME KEEPER

The head time keeper has to collect the attendance and other details for calculating monthly
wages yearly bonus and other allowances and deductions. He also calculates the terminal benefits
such as gratuity, leave salary to be paid, salary etc to workers on retirement.

The time officer maintains certain records including

2. Muster roles shift wise

3. Wage register
4. Service records
5. Over time register-daily & weekly
 6. Register of apprentices with or without pay
7. Leave with wages
8. Fines
9. Gratuity & PF
10. ESI
11. Accident register
12. Overtime register etc

SECURITY OFFICE

The smooth functioning of the mill has direct connection to the security of the company.
The main objective of the security in this mill is the protection of:

1. Personnel
2. Information
3. Materials
4. Attendance leaves

The mill is protected by a boundary wall, with a single entrance. The security office is
near the entrance with 24 hrs working condition. The security section consists of security inspector
and under him one head security guard and two security guard in shift.

The security office is responsible for the safety of the mill, its properties and raw materials
and finished goods. They also look after the transport of materials both inward & outward. They
verify the incoming materials with the bill similarly the outgoing. The vehicles and the materials are
controlled by pass system and checked clearly. Identity card is provided to the workers; belongings
are checked or searched while going out.

The security section has to keep certain records including:

 Goods movement in & out register.

 Vehicles movement in & out register
 Visitor’s resistors, which includes name, purpose of visit, time of visit.

MARKETING DEPARTMENT
STRACTURE OF MARKETING DEPARTMENT

MARKETING
MANAGER

ASSIATANT
MANAGER

DEALERS

AGENTS

The target market of sowmiya is the tamilnadu market from there these products are purchased
by business concentrated on textile sectors. In order to avoid the ware housing and storage in
CUSTOMERS
tamilnadu these products are transferred to agents present in tamilnadu that is sowmiya products
are marketed through “depot marketing”.

Depot marketing means the agents act as intermediaries. Sowmiya 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

Sowmiya has 2 agents in tamilnadu .they are ramalingalkaland nandalal brothers and sathyam
enterprise. Sowmiya market their product to certain parts of TAMILNADU 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 sowmiya are carded yarn,
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 SOWMIYA inside TAMILNADU
is not worth because the firm is marketing its products mainly outside TAMILNADU 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 TAMILNADU, 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 SOWMIYA , 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 SOWMIYA.

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.

Product profile

Cotton yarn is the product and they will be in yarn cones.

 One cone’s weight will be 1.25Kgs.

 One bag will have of 40 cones and the weight of one bag will be 50Kgs.

 160 bags will be there in one load.

Marketing functions
 The main function of the company is that to provide the best standard yarn to
the companies who needs, and so by that a better quality cloth can be produced. If
better quality yarn is produced then soon there will be a high demand and likewise
there will be external demand increased. And so the export also takes place. By this a
huge revenue also will be got for the Government. The other main aim of the
marketing department is that if there is an order then soon without any delay the
product should be reached at hands of the customers.

Developing marketing strategies

Capturing marketing insights

Connecting with customers

Building strong brand image

Delivering value to customers

Product distribution channels

Will be mainly taking care of the product, they will be calling for
tender and who quotes the best price to them the yarn will be sold. If there is
no sales then the yarns will be taken to the god owns which are situated at
Bombay and form their it will be sold.
Marketing strategy

According to the customer need and requirement the production takes place.
And the quality of the yarn also will be highly maintained. Mainly the change of the
demand will be like the yarn’s count so according to the change of the demand for the
yarn, the market demanded yarn will be produced.
Target achievement methods
 The target is fixed only after the confirmation of the value of goods in market
and if the demand for the goods in the market is high or if any order is placed then
according to the order, the production process takes place.
marketing product lines

The product lines of the cotton mill was marketed using the same channels
and by the same strategy. As per the orders and all reserved soon they will be
producing the cotton yarn as fast as they can and their by supplying to them.
Customer beneficial & satisfaction identification methods

According to the customer need and requirement the production takes place.
And the quality of the yarn also will be highly maintained. Mainly the change of the
demand will be like the yarn’s count so according to the change of the demand for the
yarns count, the market demanded yarn will be produced
Identification of customer expectation

Each customer will be looking for their own standards of cotton yarn so each
of them needs a totally different product. So according to the customer requirement
and satisfaction they have to produce the cotton yarn and that should meet the
customer expectation.
Customer fulfillment and service

As there will be orders from various customers then soon without making any
delay they will be producing the yarn and soon it will be delivered to them. As part
from the company they will be very keen about the standards of the yarn and all, as
per the order they will be producing high quality yarns and that will be delivered to
them.
Customer order receive and follow up
 The company will be getting different quotations and all from various
companies and all from that they will be choosing the best that will be beneficial to
the company. On the other side a major part of the orders and all will be taken by
SOWMIYA and they will be allotting to which customer they have to give the yarns.
When the orders are received soon the production for the order starts up and soon it
will be delivered to them.

Marketing tools & techniques

A marketing strategy is an overall marketing plan designed to meet the needs

and requirements of customers. The plan should be based on clear objectives. A
number of techniques will then be employed to make sure that the marketing plan is
effectively delivered. Marketing techniques are the tools used by the marketing
department. The marketing department will set out to identify the include public
relations, trade and consumer promotions, point-of-sale materials, editorial, publicity
and sales literature.

Market research enables the organization to identify the most appropriate marketing
mix. The mix should consist of:

The right product

Sold at the right price

In the right place

Using the most suitable promotional techniques.

Market demand for their product

As cloth is one of the basic necessity for man so for producing cloth there is
the need for the yarn so every year the demand for the yarn is increasing.
Demand analysis
 While the production is going on SOWMIYA will be looking for the sales by
giving add on newspapers and all and likewise there will be some quotations and
from all that they will be looking for which product they gets more orders and by
analyzing those things SOWMIYA will be saying that what type of yarn to be
produced
Methods of overcoming competitors

The best method of overcoming the competitors is by supplying the best

verity of yarn with high quality. And selling that yarn by market rate price. By this
the customers will be always be there.
Market segmentation

Market segmentation is mainly like

Domestic

State

National

International

Advertisement & sales promotion

As the population is increasing day by day, the need for the cloth also
increases as it is one of the basic essentials for man. And so for producing the cloth
the yarn is required. There has been a steady increase of the demand for the yarn. As
part of sales there have not been any high advertisement but providing the high
quality yarn is one of the promotion that the company is getting. Apart from all these
there have been quotations for sales and all which will be published in websites.
Product publicity
 There is no big publicity for the product but product sales tender notice will
be advertised in internet and in newspapers as well.
Customer relationship management

Customer relationship management (CRM) is a broadly recognized, widely-

implemented strategy for managing and nurturing a company’s interactions with
customers, clients and sales prospects. It involves using technology to organize,
automate, and synchronize business processes—principally sales activities, but also
those for marketing, customer service, and technical support.

The overall goals are to find,

 Attract, and win new clients,

 Nurture and retain those the company already has,

 Entice former clients back into the fold, and

 Reduce the costs of marketing and client service.

Customer relationship management denotes a company-wide business

strategy embracing all client-facing departments and even beyond. When an
implementation is effective, people, processes, and technology work in synergy to
increase profitability, and reduce operational costs.
Customer Retain Management

An effective system of communication should provide opportunities for

customer information. The customer is the ultimate object whose satisfaction and
goodwill are of the utmost importance for the success of an organization. In carrying
out the sales function of planning, the management must communicate with
customers. There were times when the customer was not the central figure. But today
the customer is the kingpin and sovereign of the market whose needs and satisfaction,
and the winning of whose goodwill, is of prime importance in these days of
 competitive setup. These must be communicated promptly. It is the communication
which establishes the contacts with the customers. Customer communication helps to
establish a relationship with customers who buy and are the sources of products. The
media used for advertisements can also be used effectively to reach the customers.
-Product selling process

There will be quotations and all which will be got from various companies
and thereby the company will be choosing the best quotation and there by the yarn
will be delivered to them. Apart from all these SOWMIYA will be playing the major
role as they will be taking initiative for selling the yarns.

FINANCE DEPARTMENT

The word finance comes from the Latin word ―fins‖. Finance is the art and
science of handling money. It is the management of money. It is the management of
laws of money. It is the management of laws of money through as organization.

Finance function is needed in all types of organizations. Of all business

functions, finance functions are the most important one. Finance function is
concerned with the evaluation of how funds are powered and used.

The definitions of finance may be grouped into following three categories.

First approach

In the words of F.W.Paish ―Finance may be defined as the provision of

money at the time it is wanted. This approach is concerned with procurement or
raising of funds and hence this is a narrow approach‖.
Second approach
 According to J.J.Hampton, ―the term finance can be defined as the
management of the flows of money through an organization, whether it will be a
corporation, school, bank or govt. agency. This a road approach.
Third approach

This is the modern approach and is the most acceptable one. According to
this approach, finance function is concerned with the procurement of funds and there
effective utilization it the business. According to the Solomon Ezra, the finance
function covers not only the raising of funds but also their effective utilization in the
business. This approach is related in the business. This approach is related in the
business. This approach is related with the financial decision making ie. The
financial manager should consider the alternative uses and sources f funds. In short,
finance function is defined as provision of money at the time when it needed.

To check all the vouchers, bills, receipts.

To draw money from the bank for any cash transactions.

To pay the amount due to the supplier outstanding and creditors.

To pay the amount to the tender purchases.

To check all the register relating to accounts section.

To prepare and furnish all furnish all return and remitting the sales tax
and central excise and other local taxes and rates.
Sending of periodical returns and remitting the sales tax and central excise
and other local taxes and rates.
The accounts department should pay salaries, wages and other monetary
benefits to the workers and staffs.

STRUCTURE OF FINANCE DEPARTMENT

 FINANCE MANAGER

SENIOR ACCOUNTANT

JUNIOR ACCOUNTANT

CASHIER

CLERCK

PEON

GENERAL RECORDS OF THE COMPANY

 Daily wages record

 Material requisition book

 Pass book
  Stores record

 Cash book

FOLLOWING BOOKS ARE MAINTAINED IN ACCOUNTS DEPARTMENT

 Daily Journals

 Sales book

 Purchases book

 Ledger

 Trading Account

 Profit & Loss Account

 Balance sheet

OPPURTUNITIES

The scope for Indian textile Industries is widening day-to-day. The share of
Indian textile industries in the international markets is expected to increase manifold
in the coming years.

THREATS

General recessions in the economy have its impact on the textile industry as well.
In order to cope up with the highly competitive and fashion sensitive International markets
for textile efforts to modernize the machineries on a continuous basis should be undertaken
without any hesitation.

Types of asset & liability

 ASSETS

Free hold

Lease hold

Building

Plant & machinery

Electrical

Furniture

Office equipments

Computers

Vehicles

Canteen

Libr
ary
LIABILI
LITIES
 SOWMIYA current account

 Inter unit dues

1. Term loan from Kottayam textiles

2. Edarikkode textiles

3. Prabhuram mills

Investment

 Investments : 168 Nos. ―B‖ class shares of Rs 100/- per share in

Malabar Spinning & Weaving Employees Multipurpose Co-op.
 Society Ltd.
 H.O. investment for revival

 Investment by Head office

 Grant from Govt of TAMILNADU Investment for modernization by

SOWMIYA

Tax payment

Rates & Taxes:

31556.00
License
fee:24473.00
Total: 56029.00
Fringe benefits given to employees

Company car

Accommodation or reimbursement of rental charges

Medical bills reimbursement or free medical care for employee (extending for
the family as well and/ or children)
Subsidized meals. Employees are given discounted meal coupons at the office
cafeteria or given a fixed allowance for meals of their choice
Gifts in cash or kind during festivals

Every employee will be registered in Employee State Insurance Corporation.

Internal Rate of Return for investment

The internal rate of return (IRR) is a rate of return used in capital budgeting to
measure and compare the profitability of investments. It is also called the discounted
 cash flow rate of return (DCFROR) or simply the rate of return (ROR). In the context
of savings and loans the IRR is also called the effective interest rate. The term
internal refers to the fact that its calculation does not incorporate environmental
factors (e.g., the interest rate or inflation).The internal rate of return on an investment
or project is the annualized effective compounded return rate or discount rate that
makes the net present value of all cash flows (both positive and negative) from a
particular investment equal to zero.
In more specific terms, the IRR of an investment is the interest rate at which
the net present value of costs (negative cash flows) of the investment equal the net
present value of the benefits (positive cash flows) of the investment. Internal rates of
return are commonly used to evaluate the desirability of investments or projects. The
higher a project's internal rate of return, the more desirable it is to undertake the
project. Assuming all other factors are equal among the various projects, the project
with the highest IRR would probably be considered the best and undertaken first.

SYSTEM DEPARTMENT

Artificial intelligence is necessary for development of mankind. Today, the

term information technology has ballooned to encompass many aspects of computing
and technology, and the term is more recognizable than ever before. The information
technology umbrella can be quite large, covering many fields. IT professionals
perform a variety of duties that range from installing applications to designing
complex computer networks and information databases.

-Duties that officials perform in it department include:

Data management, Computer networking, Computer engineering, Database

systems design, Software design, Management of information systems, Systems
management or System administration.
-OBJECTIVES

1. Ensure the protection and security of data.

2. Minimize duplication of effort, services and resources.
3. Eliminate inefficient and costly redundancies.
4. Eliminate non-compatible standards and architectures.

5. Identify obstacles for departments wanting to move computing operations

to the Division of Information Technology and solve it immediately.

-Software configuration

ESSL[enterprise Software Solutions Lab]

Microsoft office

Tally-9

ESSL is used to assist the attendance system. Personal Attendance Monitoring

System (PAMS) is the most modern technology to record the attendance of the
employees within the organizations. Biometric finger initialization technology is
adopted by the cotton mills.

Hardware Specification

eSSL-manufactured Hardware

Attendance Device

Access Control Device

Biometric Option - Fingerprint

Card Option - Proximity/MIFARE/HID

Sensor Type: Optical or Silicon Sensor

User Capacity – 1500-8000 (if only Fingerprint punch)

 User Capacity – 60,000 (if Fingerprint punch Card)

Transaction Storage - 30,000 – 100,000

Display – TFT or LCD

Verification Time – 1 to 2 Second

Connection Options

Serial

Ethernet

Wireless Ethernet

GPRS

Intranet

Internet

BENEFITS

o Reduce the time required to schedule employees

o Do away with timecard preparation, collection, filling and storage

o Significantly cut down on payroll processing time

o Eliminate unauthorized hours

o Eliminate the need to calculate vacation, sick or compensation time accruals

o Identify and eliminate time abuses (break, meal, buddy punching, etc.)

o Be more productive, efficient and profitable

o Restrict unnecessary overtime and other exceptions

o Assign resources more effectively and reduce the time needed to schedule
employees

o Altogether eliminate the need to calculate time cards Improves employee

productivity
 o Microsoft office is used for other office related activities.

o Tally-9 software is used for keeping the accounts and all

o All the accounts are computerized, when we switch over to computerized

accounting for first time.

o We should create all ledgers and enter opening balance and classify at this stage.
Just enter all the transaction in vouchers, click the journalisation, posting to
ledger, preparation to trail balance, financial statement etc, is done by the
computer.

o The software tally 9 version is used by the company.

Hardware

Processor: Intel Pentium 4 and above

RAM memory: 1GB

Hard Disk: 160GB

Processor speed: 3.2 Ghz

Monitors: HCL 17‖

All accessories are of by HCL

System analysis & design

System analysis and designing was done by DGM of each units according to
the requirements of each user.

Each user was given a user name and password to protect the computer and
all system from usage of unauthorized persons.
System maintenance

System maintenance was done by Annual Maintenance Contract (AMC).

Private parties are appointed on contract basis for the maintenance of the system,
 routers, and all related accessories.

Usually the contract was given to zenith, HCL, eSSL etc. Maintenance is of
two ways; without system replacement and with system replacement. Without system
replacement is done by internally and with system replacement is done by externally.
Features of system

The systems is protected from the attack of viruses using advanced antivirus
program. All systems are interconnected with each other by a server. So it is very
easy for the office staffs and all for entering the data and all.
Pro & cons of the system

Systems has more advantages compared with the disadvantages, the system
help to complete the work in stipulated time with precision. Because of the server all
the computers are inter-connected and so by this the staffs don’t want to rush out
from office to office or by system to systems. The only disadvantages is that it is
machine and there is a chance of problems which result in the loss of data

ADVANTAGES

Work in stipulated time with precision.

All the computers are inter-connected
The staffs don’t want to rush out from office to office or by system to systems.

DISADVANTAGES

It is machine
There is a chance of problems which result in the loss of data.
Virus attacks will destroy data
Hacking of data of the company
Identification of error

Every week there will be the inspection team who will be there for finding out
 the errors of the system. If there has been any error occurred then soon they will be
taking the necessary actions to overcome the error.
Error handling methods

If there has been any virus threat or like that, then soon they will scan the
system and remove the virus from the system.
Client server technology

Cotton mills have leased lines of BSNL to facilitate their communications

across internationally. Microsoft windows 2003 operating system is using in the
servers.. Only administrator can access the servers.
Database administration

Tally9, Microsoft Access are the two databases which is used in the company. The
administrator has the privilege to edit and handle the data in the database

CHAPTER IV

SWOT ANALYSIS

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

WEAKNESS

 Mill is highly depending on the availability of cotton as raw material from other state of
India
 The main customer of sowmiya is 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 company is its competitors especially from the tamilnadu 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

CHAPTER V

FINDING, SUGGESTION AND CONCLUSION

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
 Sowmiya spinning mills 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.

CONCLUSION

The organizational study under taken gives an insight in to the function of the SOWMIYA
SPINNING MILLS AT COIMBATORE. The structure of the mill is well planned and
organized. The management is having a good control in the day to day functioning of the
company. However it is not in position to control the workers absenteeism. Due to various
reasons there is more of labor problem due to the 100 days work scheme by the state government
which affects greatly on the production capacity of the company. And also the fluctuation of
power supply greatly affects the production process. The modernization program of introducing
automated machineries and power generators will be an answer to these problems.

The financial position is also not sound due to the loss incurring by the mill. The modernization
programmers will be an answer to this problem also to some extent, the quality improvement if
undertaken will boost the export and their by improve the financial position.

The study has helped extensively to understand the various function and problem being faced by
a manufacturing company.

REFERENCES
BOOKS:

 Article: India today: The spinning industry, September 1, 2000

 Principles of Yarn Production, Burkhard Wulfhorst, Thomas Gries.
 Selecting Cotton Bales by Spinning Consistency Index, Abhijt Majumdar, Prabal Kumar.
 Human Resource Management, K. Aswathappa, Himalaya Publication, 2003.
 Marketing Management, by Philip Kotler, 13th Revised Edition, Pearson Education.
 Production and Operation Management, : K.Aswathappa and K.Shridhara Bhat

WEB:

 http://www.textileinfo.com
 http://yarnspinning.co.cc
 http://www.nuspin.nustreet.com
 http://cotcorp.gov.in/production.asp
 http://www.hinduonnet.com/businessline/iw/2001/01/28/stories/0528e051.htm
 http://www.business-standard.com/india/news/shortagequality-cotton-revisits-yarn-
industry/219276/
 www.fibre2fashion.com/news/textile-news/index.aspx