The textile industry in India traditionally, after agriculture, is the only industry that has

generated huge employment for both skilled and unskilled labour in textiles. The textile
industry continues to be the second-largest employment generating sector in India. It offers direct
employment to over 35 million in the country.

The share of textiles in total exports was 11.04% during April–July 2010, as per
the Ministry of Textiles. During 2009–2010, the Indian textile industry was pegged at US$55
billion, 64% of which services domestic demand. In 2010, there were 2,500 textile weaving
factories and 4,135 textile finishing factories in all of India. According to AT Kearney’s ‘Retail
Apparel Index’, India was ranked as the fourth most promising market for apparel retailers in 2009.

India is first in global jute production and shares 63% of the global textile and garment
market. India is second in global textile manufacturing and also second in silk and cotton
production. 100% FDI is allowed via automatic route in textile sector. Rieter, Trutzschler, Saurer,
Soktas, Zambiati, Bilsar, Monti, CMT, E-land, Nisshinbo, Marks & Spencer, Zara, Promod,
Benetton, and Levi’s are some of the foreign textile companies invested or working in India

History

The archaeological surveys and studies have found that the people of Harrapan
civilization knew weaving and the spinning of cotton four thousand years ago. Reference to
weaving and spinning materials is found in the Vedic Literature. There was textile trade in India
during the early centuries.

A block printed and resist-dyed fabric, whose origin is from Gujaratwas found in the tombs
of Fostat, Egypt. This proves that Indian export of cotton textiles to the Egypt or the Nile
Civilization in medieval times were to a large extent. Large quantity of north Indian silk were
traded through the silk route in China to the western countries.

The Indian silks were often exchanged with the western countries for their spices in
the barter system. During the late 17th and 18th century there were large export of the Indian cotton
to the western countries to meet the need of the European industries during industrial revolution. .
Production

India is the second largest producer of fibre in the world and the major fibre produced
is cotton. Other fibres produced in India include silk, jute, wool, and man-made fibers. 60% of the
Indian textile Industry is cotton based. The strong domestic demand and the revival of the
Economic markets by 2009 has led to huge growth of the Indian textiles industry. In December
2010, the domestic cotton price was up by 50% as compared to the December 2009 prices.

The causes behind high cotton price are due to the floods in Pakistan and China . India
projected a high production of textile (325 lakh bales for 2010 -11). There has been increase in
India's share of global textile trading to seven percent in five years.The rising prices are the major
concern of the domestic producers of the country.

Man Made Fibres :

This includes manufacturing of clothes using fibre or filament synthetic yarns. It is

produced in the large power loom factories. They account for the largest sector of the textile
production in India. This sector has a share of 62% of the India's total production and provides
employment to about 4.8 million people.

The Cotton Sector :

It is the second most developed sector in the Indian Textile industries. It provides
employment to a huge number of people but its productions and employment is seasonal
depending upon the seasonal nature of the production.

The Handloom Sector :

It is well developed and is mainly dependent on the SHGs for their funds. Its market share
is 13%. of the total cloth produced in India.

The Woolen Sector :

India is the 7th largest producer. of the wool in the world. India also produces 1.8% of the
world's total wool.
The Jute Sector :

The jute or the golden fibre in India is mainly produced in the Eastern states of India like
Assam and West Bengal. India is the largest producer of jute in the world.

The Sericulture and Silk Sector :

India is the second largest producer of silk in the world. India produces 18% of the world's
total silk. Mulberry, Eri, Tasar, and Muga are the main types of silk produced in the country. It is
a labour-intensive sector.

Cotton textile

In the early years, the cotton textile industry was concentrated in the cotton growing belt
of Rajasthan, Maharashtra and Gujarat. Availability of raw materials, market, transport, labour,
moist climate and other factors contributed to localisation. In the early twentieth century, this
industry played a huge role in Bombay's economy but soon declined after independence.

While spinning continues to be centralised in Maharashtra, Gujarat and Tamil Nadu,

weaving is highly decentralised. As of 30 September 2013, there are 1,962 cotton textile mills in
India, of which about 18% are in the private sector and the rest in the public and cooperative sector.
Apart from these, there are several thousand small factories with three to ten looms.

India exports yarn to Japan, United States, United Kingdom, Russia, France, Nepal,
Singapore, Sri Lanka and other countries. India has the second-largest installed capacity of
spindles in the world, with 43.13 million spindles (30 March 2011) after China. Although India
has a large share in world trade of cotton yarn, its trade in garments is only 4% of the world's total.

Jute textiles

India is the largest producer of raw jute and jute goods and the second largest exporter after
Bangladesh. There were about 80 jute mills in India in 2010-11, most of which are located in West
Bengal, mainly along the banks of the Hooghly River, in a narrow belt (98 km long and 3 km wide).
In 2010-2011 the jute industry was supporting 0.37 million workers directly and another 400,000
small and marginal farmers who were engaged in the cultivation of jute.

Challenges faced by the industry include stiff competition in the international market from
synthetic substitutes and from other countries such as Bangladesh, Brazil, Philippines, Egypt and
Thailand. However, the internal demand has been on the rise due to Government policy of
mandatory use of jute packaging. To stimulate demand, the products need to be diversified. In
2005, the National Jute Policy was formulated with the objective of improving quality, increasing
productivity and enhancing the yield of the crop.

The main markets for jute are the United States, Canada, Russia, United
Kingdom and Australia.

Ministry of textiles and organizations

Government of India passed the National Textile Policy in 2000. The major functions of
the ministry of textiles are formulating policy and coordination of man-made fiber, cotton, jute,
silk, wool industries, decentralization of power loom sector, promotion of exports, planning &
economic analysis, finance and promoting use of information technology.

The advisory boards for the ministry include All India Handlooms Board, All India
Handicrafts Board, All India Power looms Board, Advisory Committee under Handlooms
Reservation of Articles for Production and Co-ordination Council of Textiles Research
Association. There are several public sector units and textile research associations across the
country.

Textile Industry & Market Growth in India

India’s textiles sector is one of the oldest industries in Indian economy dating back several
centuries. India's overall textile exports during FY 2017-18 stood at US$ 39.2 billion in FY18 and
is expected to increase to US$ 82.00 billion by 2021 from US$ 31.65 billion in FY19.

The Indian textiles industry is extremely varied, with the hand-spun and hand-woven
textiles sectors at one end of the spectrum, while the capital intensive sophisticated mills sector at
the other end of the spectrum. The decentralised power looms/ hosiery and knitting sector form
the largest component of the textiles sector. The close linkage of the textile industry to agriculture
(for raw materials such as cotton) and the ancient culture and traditions of the country in terms of
textiles make the Indian textiles sector unique in comparison to the industries of other countries.
The Indian textile industry has the capacity to produce a wide variety of products suitable to
different market segments, both within India and across the world.

Market Size

The Indian textiles industry, currently estimated at around US$ 150 billion, is expected to
reach US$ 250 billion by 2019. India’s textiles industry contributed seven per cent of the industry
output (in value terms) of India in 2017-18.It contributed two per cent to the GDP of India and
employs more than 45 million people in 2017-18.The sector contributed 15 per cent to the export
earnings of India in 2017-18.

The production of raw cotton in India is estimated to have reached 36.1 million bales in
FY19.

Investment

The textiles sector has witnessed a spurt in investment during the last five years. The
industry (including dyed and printed) attracted Foreign Direct Investment (FDI) worth US$ 3.09
billion during April 2000 to December 2018.

Some of the major investments in the Indian textiles industry are as follows:

 In May 2018, textiles sector recorded investments worth Rs 27,000 crore (US$ 4.19 billion)
since June 2017.

 The Government of India announced a Special Package to boost exports by US$ 31 billion,
create one crore job opportunities and attract investments worth Rs 800.00 billion
(US$ 11.93 billion) during 2018-2020. As of August 2018, it generated additional
investments worth Rs 253.45 billion (US$ 3.78 billion) and exports worth Rs 57.28 billion
(US$ 854.42 million).
Government Initiatives

The Indian government has come up with a number of export promotion policies for the
textiles sector. It has also allowed 100 per cent FDI in the Indian textiles sector under the automatic
route.

Initiatives taken by Government of India are:

 The Directorate General of Foreign Trade (DGFT) has revised rates for incentives under
the Merchandise Exports from India Scheme (MEIS) for two subsectors of Textiles
Industry - Readymade garments and Made ups - from 2 per cent to 4 per cent.

 As of August 2018, the Government of India has increased the basic custom duty to 20 per
cent from 10 per cent on 501 textile products, to boost Make in India and indigenous
production.

 The Government of India announced a Special Package to boost exports by US$ 31 billion,
create one crore job opportunity and attract investments worth Rs 80,000 crore (US$ 11.93
billion) during 2018-2020. As of August 2018 it generated additional investments worth
Rs 25,345 crore (US$ 3.78 billion) and exports worth Rs 57.28 billion (US$ 854.42
million).

 The Government of India has taken several measures including Amended Technology Up-
gradation Fund Scheme (A-TUFS), scheme is estimated to create employment for 35 lakh
people and enable investments worth Rs 95,000 crore (US$ 14.17 billion) by 2022.

 Integrated Wool Development Programme (IWDP) approved by Government of India to

provide support to the wool sector starting from wool rearer to end consumer which aims
to enhance the quality and increase the production during 2017-18 and 2019-20.

 The Cabinet Committee on Economic Affairs (CCEA), Government of India has approved
a new skill development scheme named 'Scheme for Capacity Building in Textile Sector
(SCBTS)' with an outlay of Rs 1,300 crore (US$ 202.9 million) from 2017-18 to 2019-20.
Achievements

Following are the achievements of the government in the past four years:

 I-ATUFS, a web-based claims monitoring and tracking mechanism was launched on April
21, 2016.

 381 new block level clusters were sanctioned.

 20 new textile parks were sanctioned

 Employment increased to 8.62 million in FY18 from 8.03 in FY15.

Road Ahead

The future for the Indian textile industry looks promising, buoyed by both strong domestic
consumption as well as export demand. With consumerism and disposable income on the rise, the
retail sector has experienced a rapid growth in the past decade with the entry of several
international players like Marks & Spencer, Guess and Next into the Indian market.

High economic growth has resulted in higher disposable income. This has led to rise in
demand for products creating a huge domestic market.
Indian Textiles and Apparel Industry Analysis

The textile and apparel industry can be broadly divided into two segments - yarn and fibre,
and processed fabrics and apparel. The domestic textile industry in India is estimated to reach
US$ 223 billion by 2021F from US$ 150 billion in November 2017, while cotton production in
India is have reached 36.1 million bales in FY19. In FY19, growth in private consumption is
expected to create strong domestic demand for textiles.

Increased penetration of organised retail, favourable demographics, and rising income

levels are likely to drive demand for textiles. Cloth production stood at 58.1 billion square metres
(provisional) in FY19P. India is the world's second largest exporter of textiles and clothing.

Textile and apparel exports from India are expected to increase to US$ 82 billion by 2021.
Exports of textiles and apparels from India reached US$ 31.65 billion in FY19. Manmade garments
remain the largest contributor to total textile and apparel exports from India.

Rising government focus and favourable policies is leading to growth in the textiles and
clothing industry. The Ministry of Textiles is encouraging investments through increasing focus
on schemes such as Technology Up-gradation Fund Scheme (TUFS). Under the Union Budget
2018-19, Rs 2,300 (US$ 355.27 million) crore have been allocated for TUFS and Rs 30 crore
(US$ 4.63 million) for the Scheme for Integrated Textile Parks, under which there are 47 ongoing
projects. In May 2018, textiles sector recorded investments worth Rs 27,000 crore (US$ 4.19
billion) since June 2017.

The Cabinet Committee on Economic Affairs (CCEA), Government of India has approved
a new skill development scheme named 'Scheme for Capacity Building in Textile Sector (SCBTS)'.
The Government of India announced a Special Package to boost exports by US$ 31 billion, create
one crore job opportunities and attract investments worth Rs 800.00 billion (US$ 11.93 billion)
during 2018-2020.

As of August 2018 it generated additional investments worth Rs 253.45 billion (US$ 3.78
billion) and exports worth Rs 57.28 billion (US$ 854.42 million). Cumulative FDI in the Indian
textiles reached US$ 3.09 billion between April 2000 to December 2018. Under Union Budget
2019-20, Government of India allocated around Rs 5,831.48 crore (US$ 808.24 million) for the
Ministry of Textiles.

The Directorate General of Foreign Trade (DGFT) has revised rates for incentives under
the Merchandise Exports from India Scheme (MEIS) for two subsectors of Textiles Industry -
Readymade garments and Made ups - from 2 per cent to 4 per cent. As of August 2018, the
Government of India has increased the basic custom duty to 20 per cent from 10 per cent on 501
textile products, to boost Make in India and indigenous production.
COMPANY PROFILE

AYM Syntex Limited manufactures and sells synthetic yarns in India. It offers bulk
continuous filament (BCF) yarns, such as air twisted, power heat set/Superba heat set,
cabled/twisted, and air entangled yarns, as well as BCF singles; and conventional dyed and textile
yarns, including partially oriented, fully drawn, draw textured, highly oriented, mono, mother FDY,
and air textured yarns. AYM Syntex Limited also exports its products. The company was formerly
known as Welspun Syntex Limited and changed its name to AYM Syntex Limited in December
2015. The company was founded in 1983 and is headquartered in Mumbai, India. AYM Syntex
Limited is a subsidiary of Mandawewala Enterprises Limited

History

It was incorporated in 1982 with plant in Silvassa which was the first texturising unit in
1988 at a capital outlay of Rs. 1.58 cr. In 1994, company expanded its base by merging with
Welspun Polydyed Ltd.

Sustainability

 As a 100% environmentally compliant company in the synthetic yarn industry, we also

remain steadfast in our commitment to eco-friendly practices.

 Our zero liquid discharge technology ensures water used in the dyeing process gets
recycled and reused over and over again.

 Our effluent treatment plant reuses as much as 85% of the water.

 Products such as Polycycle™ reiterate our efforts to preserve our planet and to conserve
resources.

Milestones

1985 : Launch of yarn dyeing and texturizing facility at Palghar

1992 : POY (Partially Oriented Yarn), FDY (Fully Drawn Yarn), Spinning and
texturizing facility launch at Silvassa.

2000 : commercialized Dope Dyeing

2004 : Initiated mono yarn manufacturing, again for the first time in India. Let to
huge import substitution.

2012 : Pioneered manufacturing of BCF yarn for the floor covering Industry.

2013 : Established an R & D center for innovation

2015 : Capacity Expansion in BCF

2016 : Expansion of conventional yarn dyeing on perforated tube through

automation
Management Team

“A small step for man, a giant leap for mankind”.

Neil Armstrong

MR. B.K. GOENKA [CHAIRMAN]

WELSPUN GROUP OF COMPANIES

Key Management:

Shri. B. K. Goenka - Chairman

Shri. Bhagal Ram Bijani - Sr.V.P.Of Welspun Syntex Ltd. Palghar

Shri. Sandeep Ostwal - General Manager (Production)

Our Mission

 We endeavor to reach the leadership position in each Segment / Sector of our Product /
Service.
 We are committed to satisfy our customers by providing such Quality Product / Service,
which gives highest value for money.
 We believe that employees are our most important asset through which we can reach the
top in each category of our Product / Service. Therefore, we emphasize on their all-round
development through organised training and workshops.
 We commit ourselves to continuous growth, so as to fulfill the aspirations of our Customers,
Employees and Shareholders.
Our Vision

Palghar, is a special place in the making of Welspun group. It is here that, Welspun started
its first manufacturing activity. Today, Palghar Plant houses one of the most advanced dyeing
plants of polyester, nylon yarns in India. It boasts of state-of-the-art computerised Colour Matching
system and Dyeing Technology with Automated colour-kitchen.

Palghar plant enjoys the advantages of ideal geographical location to efficiently handle all
the logistics to facilitate prompt shipments to the Indian and overseas customers. The product range
and process parameters are designed to optimise the production capacity and minimise the cost of
production without compromising on quality and offers the best value for money.

It includes package dyed polyester & nylon texturised yarns, dyed and twisted bright
trilobal polyester filament flat yarns, polyester texturised yarns twisted or untwisted on perforated
polypropylene dyeing tubes, twisted raw white/bright trilobal polyester texturised and flat yarns,
shrunk wrapped dyeing tubes for optimisation of productivity of customers, small weights and
precision wound dyed yarns.

Welspun Syntex Limited was established in 1983 and is the flagship company under the
Welspun umbrella. Since its inception WSL. has grown manifold and today is amongst the largest
manufacturers and exporters of Polyester Texturised Filament Yarn, Nylon Filament Yarn from
India.

With plants located at Silvassa and Palghar (Thane), India WSL. is well equipped to meet
the domestic as well as international demand.

It has marketing offices located at Surat and Mumbai in India that facilitate big business
ventures

Research & Development

Welspun Syntex research endeavors to transcend the refined techniques employed by the
industry on the whole. Discovering the needs and likings from a milieu of populace spanning
across 35 to 40 nations, we have geared up our processes to incorporate even the most trivial
information gathered by our exhaustive explorations.

Products:

1. POLYESTER PARTIALLY ORIENTED YARN (POY)

a) FULL DULL RAW WHITE POY

b) SEMI DULL RAW WHITE POY
c) BRIGHT RAW WHITE POY
d) SUPER BRIGHT RAW WHITE POY
e) DOPE DYED BLACK POY
f) DOPE DYED BRIGHT POY

2. POLYESTER FULLY DRAWN YARNS (FDY)

a) FULL DULL RAW WHITE FDY

b) SEMIDULL RAW WHITE FDY
c) BRIGHT RAW WHITE FDY
d) SUPER BRIGHT RAW WHITE FDY
e) BRIGHT DOPE DYED FDY
3. POLYESTER MONO FILAMENT YARNS (PMFY)

a) SEMI DULL RAW WHITE

b) BRIGHT TRILOBAL
c) DOPE DYED BLACK

4. POLYESTER FILAMENT YARN (PFY)

a) SEMI DULL RAW WHITE PFY

b) BRIGHT RAW WHITE PFY
c) SUPER WHITE RAW WHITE PFY
d) SEMI DULL DOPE DYED PFY
e) NSY (NON-SIZEING YARN WITH HIGH NIPS) PFY

5. POLYESTER DRAW TEXTURISED YARN ( DTY/PTY)

a) FULL DULL RAW WHITE PTY

b) SEMI DULL RAW WHITE PTY
c) SEMI DULL DOPE DYED BLACK PTY
d) BRIGHT DOPE DYED PTY

6. AIR TEXTURED YARNS (PATY)

a) SEMI DULL RAW WHITE

b) BRIGHT TRILOBAL RAW WHITE
c) DOPE DYED SUPER BRIGHT
d) MULTICOLOUR FANCY YARN
e) HEAVY DENIER YARNS FROM 600 DENIER TO 2100 DENIER

7. SPECIALITY POLYESTER FILAMENT YARNS (SPFY)

a) DISCAT DISPERSE & CATIONIC DYEABLE MELANGE PTY

b) BLACK AND WHITE MELANGE PTY
c) MICRO DENIER PTY
d) THICK AND THIN YARN
 e) PSY - PEACH SKIN YARN
f) BI-SHRINKAGE YARN

8. NYLON YARNS

a) RAW WHITE

b) DYED YARNS

Awards

YEAR BESTOWED
AWARD / RECOGNITION
BY

Ramkrishna Bajaj National Quality Merit Award for Welspun Indian Merchants
2012
Vidya Mandir Chamber

2011 Top 10 Green IT Enterprise Award APC- Schneider

2011 CIO100 Award 2011 CREATIVE 100

Information
2011 Information Week EDGE 2011
Week

Indian Carbon
2011 Sustainability Award for Process Innovation to Welspun India Ltd.
Outlook

Indian Shining
2011 Outstanding CSR in Textiles Sector to Welspun India Ltd.
Star CSR Awards
2011 Value Award to Welspun India Ltd. Tesco, 2010

Macy’s Inc,
2011 5 Star Award to Welspun USA Inc.
USA

2010 Special gold award for Highest Global exports TEXPROCIL

2010 Best Collaborative Planning for Supply Chain excellence Wal – Mart

The most promising new supplier of the year award in the South
2010 IKEA
Asian Region to Welspun Global Brands Ltd

National Energy
2010 First Prize in Textile Sector Award
Conservation

Gold Trophy for Highest Exports in Madeups Merchant Exporter

2010 TEXPROCIL
to Welspun Global Brands Ltd.

Gold Trophy for Highest Exports of Terry Towels in Madeups to

2010 TEXPROCIL
Welspun Global Brands Ltd.

Silver Trophy for Highest Exports of Bed Linen/Bed Sheets/Quilts

2010 TEXPROCIL
in Madeups to Welspun Global Brands Ltd.
PRESENT WORLD RENOWNED CUSTOMER, FOR WELSPUN SYNTEX LIMITED.

It is professionally managed and has highly experienced entrepreneurs and eminent

personalities on its Management Board. It has been a consistently profit making and dividend
paying company. The present list of renowned customers, for polyester Grey & dyed yarn include:

Domestic

 Reliance Industries Ltd.

 Ramchandra Singh & Bros – Maunath Bhanjan.
 Raymonds.

Export

 Cosazila, Argentina
 Textile Amarus, Spain
 Filteco, Spain
 Threelights, Srilanka
 Archmill U.K.Export
WELSPUN SYNTEX LTD. (PALGHAR)

PROCESS FLOW CHART

WELSPUN SYNTEX LTD, PALGHAR DIVISION:

A. Mumbai Setup Welspun Syntex Limited has a head office at Chira Bazaar, Mumbai and
corporate office at Lower Parel, Mumbai. The Marketing of products produced by the Palghar
plant and Purchasing of Raw material, Consumables and Parts are carried out by this office and it
also has marketing office at Surat, Gujarat.
B. Palghar plant has following machines in respective departments.

TEXTURISING DEPARTMENT :

Eight Himson Rieter Scragg (Super Draw Set), 4 Alidra Tex Machines

TWISTING DEPARTMENT :

33 Twisting Machines TFO (Two-For-One-Twister). Muratha - 9 Machines, Lohiya 140

– 14 Machines, T-Sudakoma - 5 Machines, Alidhra Tex Pro Hible - 5 Machines

DYEING DEPARTMENT :

Four Dalal yarn dyeing vessel, Nine Tex-Fab dyeing vessel, Six Thies dyeing vessel, 13
Hydro Extractor.

CONNING DEPARTMENT :

15 PCW conning, 1 Marchon, 2 Peass, 1 Alidhra, 1 Korea machine, 32 Murata Conning, 2

Texpro, 4 Fadis & 6 Rewinder.

The unit has a well-equipped chemical laboratory and a physical laboratory for testing and
ensuring product quality. The unit has been equipped with ETP and has captive power generation
units to generate 1250 KVA power.

C. Bhiwandi Godown

The Finished products of Palghar units are Dumpped / Stored in this Godown. In the name
of M/s Bidar Transport & Forwarding Agency our Delivery activities are carried out.

The present capacity of the plant is 550 tones per month of grey and dyed Polyester yarn.
Approximate annual turnover is Rs. 270 Crores on an average for the past three years

UTILITIES.

It includes captive power generation of Kirloskar Cumins with power generation capacity
of 1250 KVA. A complete effluent treatment plant (ETP) takes care of effluents
PRODUCTION CAPACITY.

The present production capacity of the Welspun Syntex division is 40 tones of polyester
yarn per day. The plant is capable of manufacturing all types of Polyester Yarn like Texturised ,
Twisted, Dyed .: -Roto/Intermingled, Micro Full Dull, Bright, Air Tex Brt, & Fancy Quality

The 4-Ps: Performance, Productivity, People with Power:

By using knowledge sharing and communication tools, Welspun managers are encouraging
employee responsibility and accountability across the organization. This is translating into
business value: there are reduced delays in response to sales orders, improved inventory control,
and streamlined accounting.

All steps in the purchase and manufacturing process are tracked so that orders are delivered
on time and to budget. This is from the time an order is generated to checks against inventory. It
covers placing production orders, materials management, stocktaking, quality assurance, shipping
and invoicing.

Dependable, Reliable, Secure

There is improved performance for users at every level on the desktop. They are
experiencing quicker start-ups and one-step shut downs, plus reduced system crashes and data loss.
This makes it easier to focus on the task in hand and address work issues, rather than the IT itself.
Reduced desktop-related user downtime and advanced Office XP recovery technology is
improving system reliability and increasing end user productivity.

Strategy for Growth

Welspun is a progressive company that has positioned itself for growth and is using IT to
achieve its vision. Mehta says: "We commit to change and appreciate the solutions that support
our commitments." The company has equipped itself with the technologies that enable it to
promote best practice throughout the organization.

Microsoft Windows Server System™ is the comprehensive, integrated, and interoperable

server infrastructure that helps reduce the complexity and costs of building, deploying, connecting,
and operating agile business solutions. Windows Server System helps customers create new value
for their business through the strategic use of their IT assets. With the Windows Server™ platform
as the foundation, Windows Server System delivers dependable infrastructure for data
management and analysis; enterprise integration; customer, partner, and employee portals;
business process automation; communications and collaboration; and core IT operations including
security, deployment, and system management.

Technology at Welspun:-

It's known that technology move mountains in business. That's one reason Welspun is
committed to technology. Through innovative technologies Welspun brings the product of minds
and imaginations to the broadest audience across the globe. We deploy the best available
technology in our diversified business to improve the quality of life, of both our employees as well
as our customers.

Besides Production Technology, Information Technology also constitutes one of the thrust
areas of the WELSPUN Group. WELSPUN has always sought to harness the benefits of
Information Technology and has envisioned using this tool in all areas of business to build up
unique competencies and efficiencies thus delivering maximum value to WELSPUN stakeholders.

The Group has implemented SAP R/3 solution across it's operations. The state of the art
communication setup consisting of voice, data and video conferencing has been put in place to
strengthen its competitive edge.

The power of IT has been further leveraged by using reverse auction and forward auction
tools developed in-house for procurement of goods & services.

In order to become a leader in highly-competitive global market, Welspun’s management

recognized that they needed a more advanced system that could deliver business critical data in
real-time to speed and enhance the decision-making process.

Welspun found just what it needed in SAP ERP solution, which improved transparency
and quality of business processes. With processes standardized and up-to-date information easily
accessible, staff now have a more accurate short and long-term overview of the business, and
inventory level across all its factories.

In just seven years, it has become a leading worldwide manufacturer by using leading-edge
IT and quality assurance at every step of the process.

The company standardized its office automation and messaging systems on Microsoft
Windows Server System, including Microsoft Windows 2000 Server and Microsoft Exchange
Server, with Microsoft Office System on the desktop. Speed of implementation and ease
of integration with other applications were crucial factors in the success of the project

SAP (Systems, Applications and Products in Data Processing)

SAP R/3 INTEGRATION MODULE

Sales order

CUSTOMER shipment SALES &

Material availability check

DISTRIBUTION

Transfer of requirements
Credit limit

Goods issue to SO
Sales Forecast / plan INVOICE

SALES &
Production order DISTRIBUTION

SALES & Production order receipt

DISTRIBUTION

A/C department
Production cost

Purchase order

Invoice receipt

Goods receipt

SALES &
DISTRIBUTION CUSTOMER
 SAP is the fourth largest software company in the world. It ranks after Microsoft, IBM and
Oracle in terms of market capitalization. SAP is the largest Enterprise Resource Planning (ERP)
solution software provider.SAP's products focus on ERP, which it helped to pioneer. The
company's main product is SAP R/3; the "R" stands for real time data processing and the number
3 relates to a three-tier application architecture: database, application server and client SAPgui.

SAP is a completely integrated, Enterprise wide information system that replaces legacy
systems with a series of software modules that communicate with each other seamlessly, replacing
current business processes with best practices. In layperson’s terms, sap software is a total
information system that weaves together all the data from manufacturing with all the data from
inventory with all the data from purchasing with all the data from accounting with all the data from
sales......ad infinitum

SAP R/3 MODULE

PRODUCTION PLANNING BASIC DATA
Planning Strategy – Make-to Stock

✓ Make product for stock in expectation of customer sales

✓ Plan using planned independent requirements for “anonymous” make-to-stock
production.
✓ Use Net or Gross Requirements Planning
 Net Requirements -- includes warehouse stock, planned issues and receipts
 Gross Requirements -- excludes warehouse stock. Just includes planned and open
orders
✓ Example is a shelf stock item such as a bike accessory light
✓ Planning Requirement Type is LSF - make to stock which is used in the planned
independent requirements transaction
✓ Sales Order Requirement is KSL - which is sale from stock
Cost Objects with Make-to-Order Production

Objects of integrated R/3 modules reflected uniquely

 Material number (MM)

 Production order, operation (PP)
 Sales order (SD)
 Project item (PS)
 Network (PS)
 CO order (CO)

WELSPUN SYNTEX LTD. And it’s manufacturing and Marketing cycle

Material Requisition and Purchase of Raw Material from

the vendors like Reliance, Indorama and Modern.

Raw material will send by the vendors, along with

Challan and Invoice.

Gatekeeper or Watchman make inward of invoice and

challan with the record of the lorry No. quantity of the
goods, vendors name, the date and time having with
Gate Pass.

The sample of raw material [R/M] sends to Quality

Control Dept. for the inspection of the quality, whether
the quality is up to the mark as per the confirmed by SOP
& ISO and the QC dept. give his approval for the
production

Accounts department make the Goods Received Note

[GRN] of the Raw Material that they have received the
particular goods send by the vendors

Before production of any goods the whole management

After making of
(production (GRN), Themake
department) R/m send in godown
the planning forthe
with the
store.
help of HOD of concern department of text., twist and
dyeing that whether we have proper inventory, free
Issue of R/m
machine, forwork
and manufacturing
place for theof production.
the finishedCompany
goods like
dyedproduces
mostly yarn, text.
theyarn as per
goods the make-to
on the requirement–order
strategy.
 The production process is the R/m (polyester,
nylon)texturising  TFO (Twisting)dyeing  conning
 packaging  batch no.  dispatching of the goods to
the party.
Since it is the make to order production, no need of
storing in warehouse

Sales department make the sales order and forward to

the factory to dispatch the goods to the party.

Dispatch department make the challan and gate pass

of the dispatching goods and arranging the vehicle for
the transportation.

Accounts department make the tax invoice and levying

excise on the goods.

Dispatch department forward the challan, gate pass

with invoice to the gatekeeper who make the entry in
the outward register and affixing the stamp and give
it to the lorry driver

Lorry driver dispatch the goods to the party and come

with a copy of GRN and submit it to the factory.
TEXTURISING OF THE R/M AND IT’S PROCESS

Texturising department:

There are six-texturising machine in the Welspun syntex limited to texturised the raw
material yarn. On the first floor, there are four machine has been set up and two machine have
been set up at the second floor. Mr. Vasudev Mali is the Head of Department. He work under the
Mr. Sandeep Ostwal who is the General Manager of Production. The HoDs of the texturised
departments, twisting, dyeing and conning and G.M. Production come together and make the
planning for the production as per the order received from the marketing and sales department
from the Chira Bazar in Mumbai in the presence of Sr. Vice President Mr. Bhagalramji.

After making the planning to production of the goods, the raw material is going to first of
all to texturised, then it is go to the twisting as per the party requirement that whether they want
twisted dyed yarn or only texturised dyed yarn. So the texturising is the basic criteria of the
company before dyeing of the yarn.

The name of the machine is Himson Draw Set 700/600 purchased from the England based
company Rieter Scragg. Company having the eight Himson Draw set 700 & Four Alidra machine.

Description of the component of texturising machine of the Welspun

The machines that have been purchase from the England named Himson super draw set
700 having divided in to the sections. First of all the machine is divided into two sides. Each side
contains 11 sections. And each section contains12 spindle hence it contain totally 264 spindle in
both side.

These are the component of the texturised machine and in detail description is mentions
below—

The machine contain the input roller, primary heater, cooing plate, positor, intermediate
roller, secondary heater, output roller and take up drum.
Efficiency of the texturising Machine:

The production efficiency of the machine is totally depending upon the denier of yarn and
round per minute (RPM) of the gears of the machines.

Hence we can say in the mathematically form it can be show in the following form

Production Efficiency of machine ∝ denier of the yarn and rpm of the pulley

As example:

If we are texturised the POY of having denier 150 and 643 round per minute of the pulley,
then the production of texturised material yarn will be approximately 3.5 tones to 4.0 tones in 24
hours running machine.

Texturising Process:

There are two types of raw material are texturised. These are the Polyester and Nylon.

1. Polyester’s Texturising Process

I. First of all the raw material PoY {Poly oriented yarn} are loaded on the Crewel. On a
crewel we can load near about 12 bundle of the raw material. At a time only six bundle of
PoY are gone to texturised and remaining six bundle are used for emergency use to prevent
the wastage and shutting down of machine that they can load the thread immediately
without the wasting of time.
II. After that the raw material goes through the Safety Pipes to preventing the yarn do not
make role each other. Then yarn is gone through the input roller. The primary roller draws
the PoY yarn in a limit, which is already affixed, by the fitter and management.
III. Now yarn goes into the Primary Heater where it is heated up to 195°C to 200°C. By giving
this much heat the yarn become more pure and removed out all the deficiency and thread
become firmer. The temperature of the Primary Heater fixes depending upon the denier
of the thread and RPM of the pulley / gear.
IV. After heating the thread, it goes immediately in consequently Cooling Plate. Where the
temperature of the cooling plate keeps very low than the primary heater. In this period
 yarn become more stretched and the entire filament become distinct individually. So the
cooling plate plays a dominant role in the same.
V. Now the thread has become cool and sends to Positor. The Positor contains three small
discs. This is the crucial period where the yarn texturised and all the filament of yarn
become separate, soft, and dictate all the impurities.
VI. The next process after cooling the yarn it is in to Intermediatery Roller where it draws and
give the maximum tension to the yarn again within its maximum limit.
VII. Immediately the yarn goes into the Secondary Heater. Where the temperature of the
secondary maintain up to 165°C to 170°C. In this heater the Yarn become more pure all
the deficiency has been dictate.
VIII. Therefore this is the entire process of the texturising and finally the texturised yarn comes
out with the help of Output Roller. Whose role is to throw the yarn outside?

IX. Finally, the output roller throws outside yarn and it is collect on the Take up Drum. There
are two cases for the take drum, if suppose the yarn will go for the directly dyeing then
yarn will be collecting on the Spring. If suppose the yarn will go for dyeing after twisting
as per the requirement of the party, in this case the yarn will be collect on the Paper Tube
FLOW CHART OF TEXTURISING PROCESS

Received Order by the Sales department and make planning by

the management team. Requisitions of raw material PoY from the
vendors send the order to the Texturising department

The raw material PoY whether it is Polyester or Nylon, hangs

on the crewel [it is a type of stand where we can hang the
R/m]

Among those bundles only six yarns used at a time and these yarn
passes through the safety pipes.

After that yarn entered in to primary roller, where it gives the

maximum tension to the yarn.

After getting sufficient tension in primary roller, yarn goes into

the Primary Heater where the temperature of Heater
maintains up to 195C to 200C. Where the yarn purifies by
the temperature.

Now yarn goes in to the Cooling Plate, where the yarn become
cool, and ready for goes in Positor.

The Positor play an important role in this process, where the yarn
actually texturised with the help of discs. Now yarn become
softer and all the filament of yarn become distinct separately.

Now yarn goes in to the Intermediatery Roller where it gives more

tension draw it again because here yarn become full stretched.

Yarn goes into the Secondary Heater, the temperature of heater

maintain up to 165C to 170C.

And finally the yarn goes through the output roller. It through the yarn
out side and been collect on the spring of paper tube as per the
requirement.
FLOW CHART OF TEXTURISING PROCESS

Received Order by the Sales department and make planning by

the management team. Requisitions of raw material PoY from the
vendors send the order to the Texturising department

The raw material PoY whether it is Polyester or Nylon, hangs

on the crewel [it is a type of stand where we can hang the
R/m]

Among those bundles only six yarns used at a time and these yarn
passes through the safety pipes.

After that yarn entered in to primary roller, where it gives the

maximum tension to the yarn.

After getting sufficient tension in primary roller, yarn goes into

the Primary Heater where the temperature of Heater
maintains up to 195C to 200C. Where the yarn purifies by
the temperature.

Now yarn goes in to the Cooling Plate, where the yarn become
cool, and ready for goes in Positor.

The Positor play an important role in this process, where the yarn
actually texturised with the help of discs. Now yarn become
softer and all the filament of yarn become distinct separately.

Now yarn goes in to the Intermediatery Roller where it gives more

tension draw it again because here yarn become full stretched.

Yarn goes into the Secondary Heater, the temperature of heater

maintain up to 165C to 170C.

And finally the yarn goes through the output roller. It through the yarn
out side and been collect on the spring of paper tube as per the
requirement.
GRAPHICAL DEPICTION OF TEXTURISING

INPUT OF LOADING OF R/M ON SAFETY PIPE

R/M CREWEL

INPUT ROLLER
OUT PUT = TEXTURISED YARN

TAKE UP PRIMARY
DRUM HEATER

OUTPUT
ROLLER COOLING
PLATE
SECONDARY
HEATER

POSITOR
INTERMEDIATERY
ROLLER

Twisting of yarn:

Department:

Mr. Dhannaram Bajiya is the head of department of Twisting department. There is two types
of twisting has been done in the

AYM SYNTEX.Ltd. one of them is simple twisting texturised yarn and Other is the Hollow
Twisting where the particular yarn being twisted like 100 Muskan many other material which does
used in the manufacturing of Saree.
 As per the party requirement made and send the order by H.O. that the particular party
require the texturised yarn to having with Twisted of that much denier and this much TPM (Twist
Per Meter) .

An example. Suppose a party is the producer of Saree on that case 136 denier and 80 TPM
and having with double ply.

Production Planning (work order preparation)

Production Planning and Control department acts as link between company’s sales
department and its manufacturing department. To authorize the activities of PPC department for:

 Items manufactured to customer’s orders, the sales department raises order/order

acceptance. This sales order serves as a communication and an authorization for PPC
department.
 Price parts and sub-assemblies of a product, a stock order is raised by the finished parts
stores, this stock order serves as a formal request to PPC to manufacture item mentioned
there in.
 Goods manufactured to stock, a “shipment order” is raised by the sales department the
copy of which is sent to PPC department is expected to maintain inventory of finished
goods in the company’s warehouse and periodically undertake replenishment action a s
stocks are depleted.

Work order preparation in a job-order production unit:

Job order production units are those units, which manufacture job against customer’s orders.
Typical examples of job production units are ancillary and fabricators.
 Manufacturing Method

Item produced to order Item produced to stock

Receive sales programme

Receive a sales order/order
acceptance of contracted job

Prepare production
Enter sales order in ‘OA’ programme
registar

Ascertain availability of
Raise work order individual parts

Prepare shop orders for the

Convert work order into shop components, which are out of
order stock or are available in
insufficient quantities

Shop order for Shop order for Shop order for Shop order for
part ‘A’ part ‘B’ part ‘C’ part ‘D’

Order preparation in batch production:

Batch production units are those, which process the requirements of products in batches,
each batch consisting of a limited number of units.

Goods under batch or mass production are produced for stock purposes. The authority to
produce is derived from the sales programme prepared by the top executive considering market
trend and feed back from sales personnel. Such sales programmes are raised based on performance
of the preceding period.

The most common concept is to maintain inventory of finished goods and in the finished
goods stores . a separate stock card is maintained to keep track of the movement of a finished
goods from and into the stores. When the stock fo an item falls to or below its pre-fixed level, a
formal request is made to the PPC to manufacture the item. Such a request serves the purpose
similar to that of a sales order.

Production Planning (Materials Planning)

Material planning is the scientific way of determining the requirements of raw materials,
bought out parts and other and enduring their availability in the right quantities, at the right time
within minimum capital lockup. Materials planning are an integral part of production planning.
For effective inventory control, production plans are converted into materials plans. Lack of
inventory causes:

 Ill-planed purchasing of materials. Over-ordering results in over investment and

unproductive use of working capital , shortage of storage facilities, deterioration and
obsolescence of stocks, etc. under-ordering causes stock out and leads to partial
utilization of facilities.

 Leads to unwanted emergency orders which are usually processed at high cost.

 Increase workload of the purchase department, receiving stores and primary inspection
thereby increasing manpower requirement.

Factors influencing materials planning

Two major factors which influencing materials planning are:

1. The external factors, and

2. Internal factors
The external factors include: (macro factor)

1. National Economy
2. Price Trends
3. Credit Policy
4. Direct and Indirect Taxes
5. Foreign Exchange Regulation
6. Import Policy
7. International Market
8. Business Cycle

The internal factors includes (micro factor)

1. Corporate Objective
2. Technology available
3. Market demand and supply
4. Procurement lead time
5. Rejection rates (both in incoming suppliers and during manufacturing)
6. Working capital available
7. Inventory norms
8. Storage facilities
9. Nearness to sources of supply
10. Information data (supply, material substitute etc.)
11. Delegation of power
12. Communication system
13. Management policy towards stocking
14. Buyer-seller relationships
15. Company’s financial position
16. Company’s corporate image
Technique for Materials Planning:

Materials planning technique can be classified into two groups:

 Materials Planning Techniques for Direct Materials

 Materials Planning Techniques for Indirect Materials

Materials planning techniques for direct materials in turn may be further classified into two
subgroups:

1. Techniques for high value materials

2. Techniques for low value materials

Dyeing Process

Dyeing is the process of imparting colors to a textile material through a dye (colour). Dyes
are obtained from flowers, nuts, berries and other forms of vegetables and plants as well as from
animal and mineral sources. These are known as natural dyes.

The other class of dyes is known as synthetic dyes. These are based on a particular type of
chemical composition. Some of these dyes are- Acid ( Anionic) dyes, Basic ( Cationic) dyes,
Neutral- Premetalized dyes, sulfur dyes, vat dyes, reactive dyes, pigment dyes etc.

 Processing Cycle for Yarn Dyeing:

 Set the dye bath with soft water at ambient temperature and as per MLR
 Enter the RFD (Ready for Dyeing) yarn in to the processing vessel.
 Add Chemical [Code-1]. Circulate for 3 minutes (In -> Out) and hold for 10 minutes.
Drain.
 Check pH. It should be 6 - 7. Check for channeling.
 Fill cold water, add chemicals [Code-2], Circulate for 5 minutes (In -> Out) and hold
for 10 minutes.
 Raise temperature to 40°C and hold for 5 minutes.
 Add dissolved dyestuff [Code-3] in 2 to 3 portions with Out -> In circulation at 40°C.
 Raise temperature to 60°C @ 1.5°C/minute and hold for 15 minutes.
 Add Chemicals [Code-4] in two parts with In->Out circulation and run for 45 minutes.
  Check the sample and drain the dye bath.
 Rinse at room temperature for 5 minutes and drain.
 Give overflow rinse as per the dept of shade - 3 to 5 minutes.
 Fill fresh water, add chemicals [Code-5] and hold for 5 minutes. Drain.
 Fill hot water (60°C), add chemicals [Code-6] and circulate for 3 minutes.
 Raise the temperature to 95°C and run for 15 minutes. Drain.
 Rinse at 70°C for 10 minutes followed by 5 minutes overflow wash. Drain.
 Fill fresh cold water, add chemicals [Code-7] & [Code-8] and circulate for 3 minutes,
hold for 15 minutes and then drain.
 Fill Cold water, add chemicals [Code-9], circulate for 3 minutes and hold for 10 minutes.
Drain.
 Unload the batch.

Dyeing Methods

Colour is applied to fabric by different methods of dyeing for different types of fiber and
at different stages of the textile production process. These methods include Direct dyeing; Stock
dyeing; Top dyeing; Yarn dyeing; Piece dyeing; Solution pigmenting or dope dyeing; Garment
dyeing etc. Of these Direct dyeing and Yarn Dyeing methods are the most popular ones.

Direct Dyeing

When a dye is applied directly to the fabric without the aid of an affixing agent, it is called
direct dyeing. In this method the dyestuff is either fermented (for natural dye) or chemically
reduced ( for synthetic vat and sulfur dyes) before being applied. The direct dyes, which are largely
used for dyeing cotton, are water soluble and can be applied directly to the fiber from an aqueous
solution. Most other classes of synthetic dye, other than vat and sulfur dyes, are also applied in
this way.
Yarn Dyeing

When dyeing is done after the fiber has been spun into yarn, it is called
Yarn dyeing. There are many forms of yarn dyeing- Skein (Hank) Dyeing,
Package Dyeing, Warp-beam Dyeing,and Space Dyeing.

Skein (Hank) Dyeing

The yarns are loosely arranged in skeins or hanks. These are then hung over a rung and
immersed in a dyebath in a large container. In this method, the colour penetration is thebest and
the yarns retain a softer, loftier feel.

Package Dyeing

The yarns are wound on spools, cones or similar units and these packages of yarn are
stacked on perforated rods in a rack and then immersed in a tank. In the tank, the dye is forced
outward from the rods under pressure through the spools and then back to the packages towards
the center to penetrate the entire yarn as thoroughly as possible.

The grey Texturised/Twisted yarn is received from Store Room the denier / tpm / lot no.
/ net weight / no.of cheeses and package sizes are verified. It is ensured that for batches from
200 kgs to 300 kgs additional five kgs of material is processed to compensate for the losses in
further processes if any. As a general rule +/- 10 percent of batch size is accepted by all customers.
The additional quantity processed for batches from 301 kgs to 650 kgs is ten kgs and for quantities
beyond 650 kgs the processing is done in two batches of 325 kgs.

The dyes and chemicals are tested in the Laboratory prior to use by drawing samples from
the drums/containers as per Product

The production processes are carried out under controlled conditions. The batch from
dyeing machine is unloaded and dyed sample is matched with Master Shade Card (QR/09/40) or
with party's sample. The sublimation and colour fastness test are conducted. The batch is sent to
Hydro Extractor with the help of hoist. The Hydro Extractor process is carried out by trained
operator.
 The product (from Hydro Extractor) in the form of cheeses either on springs or plastic tubes
are sent either to Conning or Checking & Packing area respectively.

All the effluents of dyeing departments are treated in The Effluent Treatment Plant.

Dyes are obtained from flowers, nuts, berries and others forms of vegetables and plants as
well as from animal and mineral sources. These are known as natural dyes.

The other class of dyes is known as synthetic dyes. These are based on particular type of
chemical composition. Some of these dyes are Acid (Anionic) dyes, Basic (Cationic) dyes, Natural
premetalized dyes, Sulpher dyes, Reactive dyes, Pigment dyes.

Dyeing total m/c – 22

Dalal – 4

Texfab – 9

Thies – 6

Other – 1

Hydro extractors – 13

▪ Production Capacity - 35 tons per day.

DYEING DEFECTS

SHADE DIFFERENCE DAGI (HANDLING / COLOUR)

SHADE VARATION SPOTTING

COLOUR BLEEDING WINDING PROBLEM

COLOUR FEDDING WEAK YARN

POWDER PROBLEM COLOUR DIPOSITION

LIGHT / DARK BARRE EFFECT

TONAL DIFFERENCE
DYES Pigments

Ingrain Dyes

Ready-made
dyes

Oxidation Minearal colours

Azoic

colours

Water Water
Vat Phthalo Mineral
Soluble
Insoluble Azoi Cyanine
c

Vat Sulphur Disperse

Direct
Bas Reactive
Acid
ic
CONNING

Definition – Conning – The transfer of yarn from skeins or bobbins or other types of
packages to cones.

Conning total m/c –

o Pcw (alidra) – 15
o Marchon – 1
o Murata – 32
o P.S. – 2
o Texpro – 2
o Fadis – 4
o Koria – 1
o Alidra – 1
o Rewinders – 5

Production Capacity – 30 tons per day.

Weaving Basics

The process of producing a fabric by interlacing warp and weft threads is known as
weaving. The machine used for weaving is known as weaving machine or loom. Weaving is an art
that has been practiced for thousands of years. The earliest application of weaving dates back to
the Egyptian civilization. In order to interlace wrap and weft threads to produce a fabric, the basic
mechanisms necessary on any type of looms are Primary, Secondary and Auxiliary mechanisms.

Weaving Loom Motions

Weaving is the most basic process in which two different sets of yarns or threads are
interlaced with each other to form a fabric or cloth. One of these sets is called warp which is the
lengthwise yarn running from the back to the front of the loom. The other set of crosswise yarns
are the filling which are called the weft or the woof. Therefore Weaving loom motions can be
broadly catagorised as follows:
Primary motions to produce woven fabric:

1. Shedding
2. Picking
3. Beating-up

Secondary motions

1. Let-off
2. Take-up
3. Weft selection

Auxilliary motions

1. Warp stop motions

2. Warp protectors
3. Weft stop motions
4. Weft relenishment

Warp protectors are only necessary in looms which use a free flying media to insert the
weft, such as a shuttle or a projectline. They stop the loom before beat-up can occur if the media
fails to be arrested in the correct position after it has traversed the loom.

After preparation, the warp yarn is “drawn in” through the eyes of the heald mounted on
the required shafts (harnesses).

Primary Motions

Shedding process

It is a primary motion in weaving that does separation of warp threads, according to pattern,
to allow for weft insertion or picking prior to beating. It is the mechanism that raises certain
harnesses above the others. Yarns that pass through the heald eyes in those harnesses are raised
above that are not controlled by the raised harnesses. In this way, a sheet of warp yarns is up, and
a sheet of yarns is down. The space between two yarn sheets is called “shed”.
Open shedding

It is a method of forming a shed in which, between the insertion of one weft pick and the
next, the only warp threads moved are those that are required to change position from the upper to
the lower line of the shed, or vice versa.

Semi open shedding

It is a method of forming a shed in which threads, which are to remain in the top shed line
for the next pick, are lowered a short distance and then raised again. The other threads are raised
and lowered as in open shedding.

Closed shedding

It is a method of forming a shed in which all warp threads are brought to the same level
after the insertion of each pick of weft. They are of two types i.e., bottom closed and centre closed
sheddings. The difference between them is that the terms ‘bottom’ and ‘centre’ indicate the
position of the warp threads when at rest.

Picking (weft insertion)

Picking is the second operation of the weaving process. After the shed has been formed,
the length of weft is inserted through the shed.

Beating up

Beating-up is the third operation of the weaving cycle. As soon as a weft yarn is inserted,
the reed pushes or beats-up the weft to the fell of the cloth. The fell of the cloth is the edge which
is nearest to the reed as the cloth is being woven. In other words, beating-up occurs when the reed
pushes the newly inserted weft against the fell of the cloth. Temple is a device used in weaving to
hold fabric at the fell as near as possible to the width of the warp in the reed.
Secondary Motions

Let-off (warpcontrol) motion

This is the motion which delivers warp to the weaving area at the required rate and at a
suitable constant tension by unwinding it from a flanged tube known as the weaver’s beam.

Positive let off motion - A mechanism controlling the rotation of the beam on a weaving or other
fabric forming machine where the beam is driven mechanically.

Negative let off motion - A mechanism controlling the rotation of the beam on a weaving or other
fabric forming machine where the beam is pulled round by warp against a braking force applied
to beam.

Take Up (cloth control) motion

This is the motion that withdraws fabric from the weaving area at a constant rate. It ensures
that the required pick spacing is maintained, and then winds it onto the cloth roller.

Positive take up motion

It is the motion in which the take up roller is gear driven, a change wheel or variable-throw
pawl and ratchet being provided to allow the required rate to be obtained, so determining the pick
spacing.

Negative take up motion

It is the motion in which the take up roller is rotated by means of a weight or spring, this
roller only rotates when the force applied by the weight or spring is greater than the warp lay
tension in the fabric. The take up rate is controlled by the size of the force applied by the weight
or spring and/or the warp tension
 ANALYSIS AND FINDINGS

CONTINENT WISE EXPORT DISTRIBUTION

CONTINENTS 2011-12 2010-11 2009-10

EUROPE 257628.5 177355.8 137438.3

SOUTH AMERICA 1427994 1369704 622877.2

NORTH AMERICA 254397.5 337057.7 392512.8

AFRICA 82072.29 45868.15 82985.84

ASIA 363929.7 45147.38 79449.71

TOTAL 2386022 1975133 1315264

Material in KG

Analysis :

From The above table we can see that total export of material in KG in the year 2009 – 10
is about 1315264, in the year 2010 – 11 it was 1975133 and in the year 2011 – 12 it was about
2386022.
Export

Total Export

2009 – 10 23%

2010 – 2011 42%

2011 – 2012 35%

Analysis :

From The above table we can see that total export of material in KG in the year 2009 – 10
is about 1315264, in the year 2010 – 11 it was 1975133 and in the year 2011 – 12 it was about
2386022.
 Total Export

23%

35%

42%

2009 – 10 2010 – 2011 2011 – 2012

Interpretation :

From the above graph we can see that the total export has been showing a decreasing trend
from the past years. It was highest in the year of 2010 – 2011 and in the next financial year it
decreased.
Year 2009 – 10

Export

Asia 6%

Europe 11%

South America 47%

North America 30%

Africa 6%

Analysis :

From the above table we can see that the export to Asia is 6%, to Europe it is 11%, to South
America it is 47%, to North America it is 30% and to Africa it is about 6%.
 Export

6% 6%
11%

30%

47%

Asia Europe South America North America Africa

Interpretation :

From the above graph we can see that the highest amount of export was to the South
American countries followed very closely by the export to North American countries. It was
remotely followed by the European countries.
Year 2010 - 11

Export

Asia 2%

Europe 9%

South America 70%

North America 17%

Africa 2%

Analysis :

From the above table we can see that the export to Asia is 2%, to Europe it is 9%, to South
America it is 70%, to North America it is 17% and to Africa it is about 2%.
 Export

2%2%
9%
17%

70%

Asia Europe South America North America Africa

Interpretation :

From the above graph we can see that the figures have changed drastically from the
previous year to this year. The export to North America has increased and taken almost all the
other continental figures to single digit.
Year 2011 – 12

Export

Asia 15%

Europe 11%

South America 60%

North America 11%

Africa 3%

Analysis :

From the above table we can see that the export to Asia is 15%, to Europe it is 11%, to
South America it is 60%, to North America it is 11% and to Africa it is about 3%.
 Export

3%
11% 15%

11%

60%

Asia Europe South America North America Africa

Interpretation :

From the above graph we can see that the export to South America has come down a little
and that figure has been taken up by the Asian countries. Rest of the other continents showed
approximately same figures as the previous year.
Summary of the Graphical Representation :

Looking at the graphs above it is visible that the exports has increased from year 2009 to
2011. In year 2009-10 exports were 1315264 kg i.e 23% of total exports, in year 2010-11 export
were 1975133 kg i.e. 35% of the total exports, & in year 2011-12 the exports were 2386022 kg i.e.
42% of the total exports.

Also we can see that the continent which purchase higher amount of material from AYM
Syntex Limited is Asia, but if we exclude India from Asia the second highest purchaser is South
America, the third highest purchaser is North America and the fourth highest purchaser is Europe.

Arrangement of continents in a sale wise pattern :

1. Asia.
2. South America.
3. North America.
4. Europe.
ANALYSIS OF SALE IN INDIA

Sale in India

2009 – 10 28%

2010 – 11 35%

2011 - 12 37%

Analysis :

From The above table we can see that total export of material in KG in the year 2009 – 10
is about 28%, in the year 2010 – 11 it was about 35% and in the year 2011 – 12 it was about 37%
 Sale in India

28%
37%

35%

2009 – 10 2010 – 11 2011 - 12

Interpretation :

From the above graph we can see that the sales figures in India have shown that the sales
has been improving over the years under comparison. It was lowest in the year of 2009 – 10 as
compared for three financial years under study.
Year 2009 – 10

Sale in India

Maharashtra 18%

Gujarat 15%

Karnataka 7%

Tamil Nadu 21%

Delhi 4%

Bengal 1%

Pune 12%

UP 15%

Rajasthan 1%

MP 4%

Goa 1%

Analysis :

From the above graph we can see that Sale in Goa is about 1%, in MP it is 4%, in Rajasthan
it is 1%, in UP it is 15%, in Pune it is 12% , in Bengal it is 1%, in Delhi it is 4%, in Tamil Nadu it
is 21%, in Karnataka it is 7%, in Gujarat it is 15% and in Maharashtra it is 18%.

Sale in India

Goa 1%

MP 4%

Rajasthan 1%

UP 15%

Pune 12%

Bengal 1%

Delhi 4%

Tamil Nadu 21%

Karnataka 7%

Gujarat 15%

Maharashtra 18%

0% 5% 10% 15% 20% 25%

Sale in India

Interpretation :

From the above graph we can see that the highest sale is done in the state of Tamil Nadu.
It was closely followed by the state of Maharashtra and Gujarat and Uttar Pradesh. Then it was
the city of Pune. All the other states had a single digit figures in comparison.
Year 2010 – 11

Sale in India

Maharashtra 14%

Gujarat 20%

Karnataka 9%

Tamil Nadu 22%

Delhi 3%

Bengal 1%

Pune 13%

UP 10%

Rajasthan 2%

MP 5%

Goa 1%

Analysis :

From the above graph we can see that Sale in Goa is about 1%, in MP it is 5%, in Rajasthan
it is 2%, in UP it is 10%, in Pune it is 13% , in Bengal it is 1%, in Delhi it is 3%, in Tamil Nadu it
is 22%, in Karnataka it is 9%, in Gujarat it is 20% and in Maharashtra it is 14%.

Sale in India

Goa 1%

MP 5%

Rajasthan 2%

UP 10%

Pune 13%

Bengal 1%

Delhi 3%

Tamil Nadu 22%

Karnataka 9%

Gujarat 20%

Maharashtra 14%

0% 5% 10% 15% 20% 25%

Sale in India

Interpretation :

From the above graph we can see that the sale in the state of Tamil Nadu and Gujarat have
shown an increase for this year when compared to the previous financial year. However the other
states seem to have almost the same figures.
Year 2011 – 12

Sale in India

Maharashtra 16%

Gujarat 21%

Karnataka 5%

Tamil Nadu 26%

Delhi 3%

Bengal 1%

Pune 13%

UP 10%

Rajasthan 1%

MP 3%

Analysis :

From the above graph we can see that Sale in in MP it is 3%, in Rajasthan it is 1%, in UP
it is 10%, in Pune it is 13% , in Bengal it is 1%, in Delhi it is 3%, in Tamil Nadu it is 26%, in
Karnataka it is 5%, in Gujarat it is 21% and in Maharashtra it is 16%.
 Sale in India

MP 3%

Rajasthan 1%

UP 10%

Pune 13%

Bengal 1%

Delhi 3%

Tamil Nadu 26%

Karnataka 5%

Gujarat 21%

Maharashtra 16%

0% 5% 10% 15% 20% 25% 30%

Sale in India

Interpretation :

From the above graphs we can see that the sale of AYM Syntex Ltd. Shows an stable
growth. The sale is continuously increasing each year. From the above graphs we can also see that
the states which purchases more from We AYM Syntex ltd. Are Tamilnadu, Maharashra, UP and
Gujrat. And we can also see that the sale in Tamilnadu & Gujrat are going on increasing year on
year
SWOT ANALYSIS

STRENGTH

- Zero Discharge

- Autmization Technology

WEAKNESS

- Present View

- Plant Layout

OPPORTUNITIES

- Future View

- Prevention

THREATS

- Non-Conformance

- Goodwill In Market
 CONCLUSION AND RECOMMENDATION

Company survives because of the people working in it.

 Maintaining manpower is very essential factor for any manufacturing company.

 Every person should know his duties and should perform it heartily. This can be achieved
only if the company will take interest in the people who belong to it. Company authorities
should maintain a suitable atmosphere for the people working in the company.
 Skills of operators and workers should be polished and maintained in order to improve the
efficiency in the work that they perform, this will indirectly prove beneficial for the
company.
 The manual instruments which are used in the lab, if converted to automated ones will
definitely help in saving time and the manpower which will indirectly help in the output of
the company.

Automated storage and retrieval systems (AS/RS)

AS/RS are computer-controlled systems that automate storage and retrieval of inventory,
work-in-progress (WIP) items. AS/ RS expedites the process of storage and retrieval. Besides the
chances of the product being damaged during storage and retrieval is also significantly reduced.
AS / RS is made up of four basic components, a storage rack or bin, a storage and retrieval machine
(SRM), shuttle, and a planning and control system. AVGs and AS/RS systems together can provide
fully automated systems that can update the stock after it is taken by some department or if the
stock is brought inside the company. It will keep track of all the stock and related things.