PRODUCTION AND OPERATION MANAGEMENT

PROJECT REPORT
MALABAR CO-OPERATIVE TEXTILE LIMITED

Submitted To Mrs. T. Bina Course Faculty

Submitted By Mohamed Faizal.KK 10 MBA 22

HAPPY VALLEY B-SCHOOL

2010-2012 BATCH

INTRODUCTION

Textile Industry in India is the second largest employment generator after agriculture. Indian Textile Industry contributes about 14 percentages to industrial production, 4 percent to the countrys Gross Domestic Product (GDP) and 16.63 percent to export earnings. Nearly 40 percent of the textiles produced in the country is exported. Indian textile Industry is the largest industry when it comes to employment that generates jobs not just within but also in various support industries like agriculture. MALCOTEX is a major textile industry in the Kerala state. The operation study is conducted to gain practical input about the activities and situations. It helps to understand and evaluate the various operations of the organization and production functions or activities of each production departments.

COMPANY PROFILE

Name of the Company Nature of the Company

: :

MALABAR CO OPERATIVETEXTILE LTD Spinning

Managing Director No. of Staff Working Working Hours Type of Product

: : : :

G.M Nair 262 24 Hours/Day Cotton Yarn of 60s Carded and 60s Combed Cotton Yarn

Address

Malabar Co- operative Textiles Ltd Karthala, Chungam, Athhavanad Post, Kuttippurm via Malappuram Dt, Kerala

MALABAR CO-OPERATIVETEXTILE LIMITED (MALCOTEX)

The company situated near Valanchery town Malappuram District. The company established in 1994. The company is the one of the spinning mills in Kerala State with 12034 spindles. It is a co-operative society registered under the kerala Co- operative Societies Act. The mill produces cotton yarn of 60s carded unit and 60s combed auto yarns from May 2006.

The mill produces different types of yard as requires by the weavers in and outside in Kerala State. The yarn produced by mill is also sold to the Kerala State Handloom weaves co-operative societies for distributing yarn to its members at reasonable price. Two different varieties of yarn that are being produced by the company are cotton and polyster. The company buy raw material from Maharashtra, Andhra Pradesh and Tamil Nadu. The MALCOTEX produces different types of yarns and marketed in different states of India especially Maharashtra. Yarn marketing in different from other product marketing yarn has high demand. Marketing of yarn are made through agent, Sagar Enterprise Lokmanyathilak, Mumbai, finished goods are sending to the agency for the selling the yarn according to market price. MALCOTEX faces of competition from different organization, some of them are state level and some of them are national level STATE LEVEL (LOCAL) :- Pats pin mills (Kanjikode), Parvath Mills (Kollam), Cannanore Spinning Mill (Kannur) NATIONAL LEVEL :- Mysore Spinning Mill (Bangalore), Tirupati Cotton Mill (Renigentage), Netra Spinning Mill (Secunderabad)

ORGANISATIONAL STRUCTURE

Chairman and Board of Directors

Managing Director General Manager

Mill Manager

Administration Officer

Spinning Master

Account Officer

Technical Supervisor

Finance Officer

Security Supervisor Purchase Officer Electronic and Maintenance Supervisor Sales Officer

Workers: 1. Permanent 2. Temporary 3. Trainees THE INDUSTRY

Time Keeper

Indian Textile Industry is one of the leading sector in the world. Currently it is estimated to be around US $ 11.5 billion by the year 2012. The current domestic market of textile in India is expected to be increased to US $ 60 billion by 2012 from the current US $ 34.6 billion. The textile export of the country was around US $ 19.14 billion in 2006-07, which

reach to US $ 22.13 in 2007-08. The share of export also expected to increase from 4% to 7% within 2012. Through during the year 2008-09, the industry had to face adverse agro - climatic conditions, it succeeded in producing 290 lakh bales last year, yet managed to retain its position as worlds second highest cotton producer. DEMAND FORCASTING The company said that the summer season the most demand in Cotton, because of the cotton is the suitable in the prevent heat better than other cloths. These time the demand of cotton increase and will produce more yarns. SOURCES OF PRODUCT DESIGN The industry well established in their machinery, purchased from the Lakshmi Manufacturers, Coimbatore, and the source of the product design copied from Varaprasad & Sons Agro Product Company, Gundoor. REASON FOR SELECTING PRESENT LOCATION The Company is located at Kuttippuram of Malappuram District which is near to National Highway, so available transportation facility, and availability of raw material. The location facilitates resources and highly ecolological place. Excellent infrastructure more suitable in present location. PURCHASING PRCEDURE The company purchases different raw materials from different parts of India. Raw material is completely used are raw cotton in different types. They are LIC, LRA, MCU5, MECHI AND BERMA 54. There is a purchasing committee for the purchase of raw material.

Raw cotton is purchased from Tamil Nadu, Karnataka, Andhra Pradesh, Gujarath and Mahararashtra. Samples are selected from raw materials and they are sending KSTC, SITRA for quality check. The mill accepts them only if they are required quality. TRINING There are two categories of trainees. Different stages of training are follows:Stage 1 2 Category A B Period 3 months 3 months

Two stages of Training

Only two candidates who satisfactory full fill the work load specification and working days. On stage in considered to the next stage. After the completion of fourth stage of training the trainee are treated as casuals. After working as casuals for a certain period they treated as badalies. The company spend large amount for the purpose of training in each year.

STORE ROOM

WINDING

PACKING

PRODUCTION LAYOUT

CARDING

DRAWING SIMPLEX

SPINNING

BLOW ROOM RAW MATERIALS

PRODUCTION PROCESS

MIXING

DESPACH

MIXING BLOW ROOM

CARDING

DRAWING

SIMPLEX

SPINNING

WINDING

PACKING

1. MIXING

Mixing in the first stage of production process. Mixing means the mixing raw material. Different varieties of cotton with different characteristics are mixed together by hand mixing as per requirement Awarding to the cotton, mixing 80%, polyster and 20% cotton are mixed layer by hand. One lot of mixing is looking. After mixing the raw cotton it is left for blowing for 24 hours. in mixing room , After blowing for 24 hours . It is taken into processing stage that into the room 2. BLOW ROOM The object of blow room is open the cotton thoroughly clean and make into lap form. After cleaning the mixing raw material in reeled on the iron bar and gets a mat, it is known as lap. 3. CARDING The function of carding machine is; 1
2

Removal fresh Individualisation of fiber

The lap from blow room is fed roller of machine. In this stage materials are opened and the imparities are extracted through the grid bar. The materials are passed to the wire point of the flats and short removed as waste. The long fitter is delivered from fitter in the form of web. Then the web is passed through Cylinder and delivered and collected in the container. The main of carding is to remove waste, shorten the fibre individualization of fiber and make it into sliver form. 4. DRAWING

In this machine the sliver from card fed and blended and paraysed. After this process the final firm is termed as finished sliver. The function of drawing are:
1

Paralysis of fibers : Eight number of sliver from carding is in fed to the drafting zone of the machine. There it is draftered between the rollers and delivered and sliver and collected in can. While the sliver passed through the drafting rollers due to the surface speed difference, the fiber will stretch and get paralysed due to the

Removal of irregularities of sliver : Since 8 slivers are fed a time thick and thin places in different slivers may joint together from other uniform delivery. Hence remove the irregularities.

5. SIMPEX The drafting slivers is fed in bed to the back taller of the drafting zone of the machine and due to the circumferential difference in the sliver yet drafted and form in a thin flees delivered from the front roller passed through the flayer due to the rotation of the flayer. The flees get twisted and form a role. The role is winded over the bobbins places into the spindle and bobbin. 6. SPINNING The ring frame is a yarn manufacturing machine. The function of the spinning are drafting, twisting and wending. The rolling from the bobbin is passed through the back roller due to the surface speed difference the rolling gets drafted and form into thin stands; These stand twisted due to the rotation of the spinner and ring travelers and the yarn house formed is wind over the empty bobbins places on spindle due to the weight ring traveler. 7. WINDING

We cant send the yarns into the market in the form of cops which are produced ring frames. In the market they require a continuous length and clear yarn. These functions are carried out by winding machine, the cops frame and ring frame are fed through drawn and wind over paper cones. The sickened imparities on the yarn are estimated by balder of cleaner. The yarn from the cop tide one after another and make into a continuous length and according to the required weight. 8. PACKING The cones covered in polythene bags and finally packed in hessian cloths and bag will have a net weight of 50 kg, which will be sending to market. It is completely done manually; there is no help of any machinery.

QUALITY INITIATIVE There is a quality control division working under the charge of mill manager. A random selection of six yarn length of samples of silver in is made from from the carding, drawing and simplex process. The average weight of the sliver is found and compared with standard with standard weight. The yarn from the spinning process is subject to two texts, viz. count test and lew test. The sample from the spinning process in subject to two tests. The sample from the spinning process is collected in the form of cops.

PRODUCTION SCHEDULING

The company works 24 x 7 and works throughout the week in 3 shifts the timing of shifts is given below: 1
2

8 am to 4 pm 4 pm to 2 am 12 am to 8 am

Each shift consists of an interval of 30 minutes. All the employees are given 8 national and 5 state holidays in addition to this. The workers who completed 240 working hour in a year. The MALCOTEX is now in a strong footing. By over coming various problem in the earlier stage, the company their systemayic management, good employer employee relationship and join efforts has been able to retain its standard. Almost all employees working in the company are satisfied with the present working condition and now the company not focus on expansion their business.