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PREFACE
We are going to make our project on textile industry in order to know the Manufacturing
process and Layout. This project also gives the some important information of textile industry
those brands, different product, New business, New technologies, New partnership. Because
technologies also shape corporate destines.
The Career of the Person depends upon many things. One of them is the knowledge. It
acquires through theory is not sufficient to develop. Her personality and to develop some skills,
but now a days, it is no more. Practical training is necessary to implement the theories & acquire
the knowledge, so for this purpose our institute –Global Institute of Management – affiliated by
Gujarat Technological University.
The report is made with clear objective of study of “textile industry” it’s working. The report
will give the details of Production .Our report provides you all the information related to the
Production. We hope this report fulfils need of the educational requirements.
We are heartily thankful to the Gujarat Technological University, which has given us the
golden opportunity to prepare or analyze project report of “textile industry”. We are also
thankful to honorable professor Ms.Anupama Ambujakshan who has leaded us to enlighten
ourselves in preparation of this project.
We are heartily thankful to Management Faculty without whose constant guidance this
work would have been an impossible task to complete. Her inspiration and encouragement has
leaded me to come with a successful task.
9 BIBLIOGRAPHY 28
Textile Industry Is One Of The Leading Textile Industries In The World. Though Was
Predominantly Unorganized Industry Even A Few Years Back, But The Scenario Started
Changing After The Economic Liberalization Of Indian Economy In 1991. The Opening Up Of
Economy Gave Much Needed Thrust To Textile Industry, Which Has Now Successfully Become
One Of The Largest In The World.
Indian Textile Industry Largely Depends Upon The Textile Manufacturing And Export. Its Play
A Major Role In The Economy of The Country. Indian Textile Industry Is Also The Largest In
The Country In Terms Of Employment Generation.
Indian Textile Industry Can Be Divided Into Several Segments, Some Of Which Can Be Listed
As Below:-
Cotton Textile
Silk Textile
Woolen Textile
Readymade Textile
Hand-Crafted Textile
Jute And Coir
Project
Job shop
Batch production ( disconnected line)
Assembly line
Continuous flow
Cell manufacturing (group technology)
The textile industry using the JOB-SHOP or BATCH PRODUCTION techniques for the
production.
The Weaving Process Is Characterized By Long Planning Horizons And Relatively Slow Speed
Of Machines, Very Long Setup Times, Very Large Production Batches, And Mixed Order And
Stock-Based Production. On The Contrary, The Warp Making Process Is Characterized By Short
Planning Horizons And High Speed Of Machines, Short Setup Times, Small Production Batches
And Only Orders-Based Production. The Above Phases Pose The Most Complex Production
Scheduling Problems.
JOB-SHOP techniques:-
In the job shop machinery used mostly general purpose to produce the goods.
Highly skilled labor is needed for this type of production system to handle and operate the
machinery.
Textile production systems may be treated as a succession of local problems, one per each
production phase. The coherence of these local problems should be taken into account by
“material requirements planning” or “just-in-time” approaches.
INTRODUCTION:-
Products are the goods and services produced and processes are the facilities, skills, and
technologies used to produce them. Production function or operation function is the primary
function of an industrial enterprise. It is also known as conversion process or transformation
process which transforms some of the inputs (raw material and components) into outputs which
are useful for the consumers.
SPINNING:-
Most Spinning Is Done Using Break Or Open-End Spinning, This Is A Technique
Where The Staples Are Blown By Air Into A Rotating Drum, Where They Attach
Themselves To The Tail Of Formed Yarn That Is Continually Being Drawn Out Of The
Chamber. Other Methods Of Break Spinning Use Needles And Electrostatic Forces.
This Method Has Replaced The Older Methods Of Ring And Mule Spinning. It Is Also
Easily Adapted For Artificial Fibers.
The Spinning Machine Takes The Roving, Thins It And Twists It, Creating Yarn.
In Mule Spinning The Roving Is Pulled Off A Bobbin And Fed Through Rollers,
Which Are Feeding At Several Different Speeds. This Thins The Roving At A Consistent
Rate. If The Roving Was Not A Consistent Size, Then This Step Could Cause A Break In
The Yarn, Or Could Jam The Machine. The Yarn Is Twisted Through The Spinning Of
The Bobbin As The Carriage Moves Out, And Is Rolled Onto A Cop As The Carriage
Returns. Mule Spinning Produces A Finer Thread Than The Less Skilled Ring Spinning.
WEAVING:-
Weaving Is A Method Of Fabric Production In Which Two Distinct Sets Of Yarns
Or Threads Are Interlaced At Right Angles To Form A Fabric Or Cloth. The Other
Methods Are Knitting, Lace Making, Felting, And Braiding Or Plaiting. The
Longitudinal Threads Are Called The Warp And The Lateral Threads Are The Weft Or
Filling. (WEFT OR WOOF IS AN OLD ENGLISH WORD MEANING "THAT
WHICH IS WOVEN".) The Method In Which These Threads Are Inter Woven Affects
The Characteristics Of The Cloth.
Cloth Is Usually Woven On A Loom, A Device That Holds The Warp Threads In
Place While Filling Threads Are Woven Through Them. A Fabric Band Which Meets
This Definition Of Cloth (Warp Threads With A Weft Thread Winding Between) Can
Also Be Made Using Other Methods, Including Tablet Weaving, Back-Strap, Or Other
Techniques Without Looms.
PRINTING:-
Colored Designs On Cotton Cloth Is Similar To Printing On Paper.
Cotton Fabrics Are Probably Finished In More Different Ways Than Any Other Type Of
Fabrics. Some Finishes Change The Look And Feel Of The Cotton Fabric, While Others Add
Special Characteristics Such As Durable Press, Water Repellency, Flame Resistance, Shrinkage
Control And Others. Several Different Finishes May Be Applied To A Single Fabric.
CUTTING:-
The Fabric Is Then Cut With The Help Of Cloth Cutting Machines Suitable For The
Type Of The Cloth. These Can Be Band Cutters Having Similar Work Method Like That Of
Band Saws; Cutters Having Rotary Blades; Machines Having Reciprocal Blades Which Saw Up
And Down; Die Clickers Similar To Die Or Punch Press; Or Computerized Machines That Use
Either Blades Or Laser Beams To Cut The Fabric In Desired Shapes.
Sewing:-
It Is The Most Important Department/ Section Of A Garment Manufacturing Industry. Sewing
Machines Of Different Types Are Arranged As A Vertical Line To Assemble The Garments.
Unloading
Fork lifting
Unwrapping
Cutting Ties
Waste Bailing
Feeding
Removing Lint
Movement Of Card Cans
Movement Of Drawing Cans
Spinning Yarn
Warp Filling
Winding Yarn Onto Beam
Supplying Beams
Preparing Loom Beams
Storing Loom Beams
Hoisting
Producing Fabric Rolls
Inspecting Fabric
Cutting Fabric
Wrapping
Loading
Eating
Relaxing
Storage
Personal Hygiene
Supervision
Maintenance
Air Washing/Conditioning
Lint Removal
Quality Control
Testing
Training
Monitoring
Plant location may be understood as the function of determining where the plant should
be located for maximum operating economy and effectiveness. The selection for locating
a plant is most important factor which influences the industry.
Any industry has try to locate their plant near by the market place, where transportation
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, labour force, raw material, power…etc
Popularly Termed As The Textile State Of India, Gujarat Has One Of The Most Flourishing
Textile Industries In The Country. Also Said To Be The Manchester Of The East And The
Denim Capital Of India The Textile Industry In Gujarat Contributes Almost 3% Towards The
GDP Of India. India Holds A Major Portion Of Global Textile Market Share. Textiles In Gujarat
Are Responsible For Contributing A Major Share Of India's Art And Crafts.
It Is Also Among The Oldest Industries In The State. Due To Its Perfect Combination Of Skilled
Labor, Vast Variety Of Raw Materials, Seamless Blend Of Yarns And The Use Of Traditional
Techniques The State Produces The Finest Range Of Textiles.
The Textile Industry In Gujarat Involves Quite A Sizable Chunk Of The Population. Brands Like
Arvind Mills, Parag And Praful Belong To Gujarat. More Than 90% Of The Polyester Used In
India Is Produced In Surat. The Two Major Textile Manufacturing Cities In Gujarat Are
Ahmedabad And Surat. Both These Cities Together Account For Almost 50% Of The Total
Textiles Produced In Gujarat.
Textiles in Gujarat
BANDHEJ:-
Bandhej Is The Name Given To The Tie And Dye Fabric Of Jamnagar, Mandvi And Bhuj. The
Art Of Bandhej Is Known For Its Typical Designs And Patterns. These Are Often Used In
Wedding Outfits When They Are Called Gharchola Odhni And Sarees.He Tie-Dyed Fabrics Or
The Bandhej Of Gujarat Are Certainly The Best Of Its Kind Produced In India Also Lso Known
As Bandhani Or Bandhni.The Cost Of The Bandhej Of Gujarat Rests Not Only On The Quality
Of The Fabric, But Also On The Number Of Times It Has To Be Tied And Dyed As Well As
The Intricacy Of The Pattern.
MATANI:-
Matani Or More Popularly Called Matani Pechedi Or Mata-Ni-Pachedi Are Made By The
Vaghris For The Purpose Of Various Rituals. They Employ A Combination Of Block Printing
For The Outline Of The Pattern As Well As The Painting Of The Mordants.The Matani Is
Actually A Tribute To The Mother Goddess Durga.Matani Reflects A Passion Among The
Gujaratis For Colors And A Vision For The Intricate Designs And Forms. It Is The Expression
Of An Artistic Personality As Well As Rich Cultural Heritage.
PATOLA:-
The Patola Silk from Patan Is Very Popular And One Of The Largest Selling Fabrics In The
Country. The Sarees Are A Mark Of Tradition And Grandeur Depicting Gujarat As A Land Of
Prosperity And Wealth. This Is Unique To Patan And Is Known For Its Utmost Delicate Designs
Woven With Great Expertise And Quality. Gujarat Patola Exhibits A Passion For Color And A
Deep Sense For Design And Form. They Convey A Message Of The State's Rich Cultural
Heritage.
The Indian Textile Industry Today Has Approximately 1200 Medium To Large Scale
Textile Mills In India. 20%Of These Mills Are Located In Coimbatore (Tamilnadu).
The Industry Has 34 Million Cotton Textile Spindles For Manufacturing Cotton Yarn
Which Account For 70 Percent Of India's Textile Exports. (China Has 40 Million Cotton
Spindles.)
Of The Indian Textile Yarn Exports, Almost 80 Percent Come From Coarser Yarns
(Counts Below 40's). Consequently, There Is A Need To Upgrade The Technology.
The Domestic Knitting Industry Is Characterized By Small Scale Units With Facilities
For Dyeing, Processing And Finishing. The Industry Is Concentrated In Tirupur
(Tamilnadu) And Ludhiana (Punjab). Tirupur Produces 60 Percent Of The Country's
Total Knitwear Exports.
Knitted Garments Account For Almost 32 Percent Of All Exported Garments. The Major
Players Include Nahar Spinning, Arun Processors And Jersey India.
EMPLOYMENT OPPORTUNITIES:-
The Indian Textile Industry of India is vast and growing with presence of several national and
international brands. The main segments of the Indian textile industry are Man-made Textiles,
Cotton Textiles including Handlooms, Silk Textiles, Woolen Textiles, Handicrafts, Coir,
Readymade Garments, and Jute.
Job opportunities are diverse in nature in the textile industry ranging from production, designing,
distribution and sales. The need for manpower for the textile industry is growing to keep up with
the growing demand; fresher’s are finding numerous job opportunities in the textile industry of
India.
The Indian textile industry offers opportunities to fresher's from various academic backgrounds
as nature of job is diverse. A textile engineer must have an engineering background; either B.E.
or B.Tech is preferred
The need for the selection of the location may arise under any of the following
conditions:-
1) When the business is newly started;
2) The existing business unit has outgrown its original facilities and expansion is not
possible;
3) A lease expire and the landlord does not renew the lease;
4) Other social or economic reasons; for example inadequate labour supply, shifting of
the market.
There Are Three Classic Approaches To Laying Out The Equipment And Processing Functions
Within A Manufacturing Facility.
Process Layouts Require The Most Movement Of Products From Workstation To Workstation
Since The Equipment Is Arranged Without Regard To The Processing Needs Of Any One
Product. Job Shops Can Attempt To Reduce This Unnecessary Handling, However, By
Unlike Process Layouts, However, Product Layouts Maximize The Need For Expenditures On
Equipment. Studies Have Shown That Savings In Process Efficiency Far Outweigh These
Additional Machine Costs. If Cutting Stations Are Required At Several Steps Along The
Processing Route, Product Layouts Would Require Purchasing Separate Saws For Each Step To
Allow The Uninterrupted Flow Of Work Along The Line.
Introduction:-
There Are Numerous Health And Safety (H&S) Issues Associated With The textile Industry.
These Include: Chemical Exposure From The Processing and Dyeing Of Materials; Exposure To
Cotton And Other Organic Dusts, Which Can Affect The Throat And Lungs; Musculoskeletal
Stresses; Noise exposure, Which Can Lead To Hearing Loss; Temperature And Ventilation,
Which Can Lead To Fatigue And Dehydration If Temperatures Are Too High; And Working
Hours And Breaks, Including Access To Food, Drinks And Bathroom Facilities. This Booklet
Reviews Some Key Areas Of H&S In textile Dyeing Such As The Information Present In
Material Safety Data Sheets (MSDS), Fire Hazard Training And Various Other Components Of
H&S.
Health And Safety Regulations Have Been In Place In Textile Industries Across Europe And The
USA Since The 1970s. In England, The Health And Safety At Work Act Was Introduced In The
Early 1970s And The Health And Safety Executive (HSE) Was Formed And Given
Responsibility For Providing The Framework For Workplace H&S. Different Countries Have
Different Standards On H&S Practices And This Booklet Takes Some Of The Key Elements Of
These That Are Applicable To Promoting A Safe Working Environment In The Textile Industry
In Bangladesh.
CHEMICAL SAFETY
Hazardous Chemicals and their Symbols
Material Safety Data Sheet
Risk Assessment of Chemicals
Health Effects of Dyes and Chemicals
Chemical Storage and Disposal of Waste
First Aid
LABORATORY SAFETY PROTOCOL
Laboratory Safety Protocol
Factory Floor Safety Protocol
RESPONSIBILITY
Role of The Management
Role of The Factory Staff
There Should Also Be Signs Saying “No Food And Drink” In Areas Such As The
Laboratory, Store Room And Factory Floor, And Any Other Areas Where It Is
Not Safe To Consume Food, For Example Because Of The Risk Of
Contamination By Chemicals.
Hazardous Chemicals Should Be Clearly Marked In An Appropriate Language
And With Clear Symbols That People Have Been Trained To Recognise And
Understand.
Heavy Objects Should Be Marked As Such To Avoid Musculoskeletal Accidents.
Substances Or Items That Present A Fire Hazard Should Be Clearly Labelled
With The Universally Recognized Symbol.
Signs Should Be Placed Near Inflammable Substances Stating That It Is Not
Permitted To Smoke Or Have Open Fires.
Showers And Eye Washes Should Be Made Available And Clearly Marked.
Each Employee Should Have Sufficient Appropriate Training And Experience So That They Can
Perform All Their Required Job Activities. Where Relevant Each Employee Should:
• Be Aware Of The Contents Of MSDS And Of Potential H&S Hazards.
• Follow All Protocol In The Safe Handling And Disposal Of Dyes And Chemicals.
• Be Aware Of The Fire Protocol, Where Fire Extinguishers Are And Where The Nearest Exit Is
And Where Assembly Points Are.
• Be Aware Of Where The First Aid Kit Is.
• Wash Hands Before Meals, When Leaving The Work Area And At The End Of The Shift. This
Will Prevent Accidental Ingestion Of Chemicals Or Contact With Eyes.
• Maintain Correct Posture When Lifting Or Carrying Heavy Objects.
• Report All Accidents And Sicknesses To The Manager As Soon As They Occur.
• Report Any Defects Or Problems With The Machinery That Might Lead To Potential
Accidents.
Websites:- www.cci.in
www.Rabatex.in
www.alok.in