1.

INTRODUCTION

1.1.INDUSTRY PROFILE

Textile Industry is playing an important role in the economic development in India.

There are more than 300 million employees working in this industrial sector under private

and public management next to agriculture, textile industry is the largest sector giving

employment to the people.

Cotton industry in India is the largest organized and board based institution in India.

Industry, which contributes 20% in countries total industrial production and 38% of total

exports.

Indian government established National Textile Corporation (NTC) in 1968. At

present NTC is managing 124 - textile mill in the country. The paid up capital of corporation

is Rs. 234.28 crores and about 9.5 crores meters cloth is being produced by NTC in country.

Now India earns Rs. 35000 crores every year from Textile. Industry India has more

spinning mills and looms factories next to China, the large and small scale industries are

mainly situated in Maharastra, Gujarat and Tamil Nadu in Coimbatore.

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 Coimbatore is known as Manchester of South India. In this district about 5 Lakhs

persons are directly and indirectly employed through industries. Textile sectors in the

coimbatore city has unique development area in the industrial activities.

Education is must to lie the present stage. Education is derived in two ways. The first

one is theoretical way and the other is practical way. Education becomes valid when it is

properly used for the practical purpose. It can be achieved through the gateway of industrial

training and research studies by keeping the above points in mind. The ADITYA

INSTITUTE OF TECHNOLOGY has the industrial training as important components of

education for the students of school of management studies. These two connect theoretical to

practical purpose under the placement training. We were to undergo the training in industry

for 6 weeks. We have undergone the training at the Together Textile Mills India Private

Limited.

The textile industry is one of the largest foreign exchange earners. Accounting for

nearly 16-18% of the countries total exports. India supplies 28-30% of World’s apparel

market. A percentage that has unfortunately remained stable for past 15 years. The Indian

apparel export and domestic export catered by 3000 manufacturing units spread over places

like Mumbai, Delhi, Tirupur, Coimbatore, Kolkatta, Ludhiana, Bangalore, Etc… These

employee 3-5 million people in manufacturing and allied activities.

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 1.2.COMPANY PROFILE

Together Textile Mills India Private Limited was established in the year 1997. This is

a composite mill(all under one roof). The company which is backed by competent managerial

foresight an quick decision making policies. The company is equipped with top of the line

plant and machinery and state of the art.

Infrastructure employing about 500 workers. They convert Grey yarn to Fabric. They

do with dyeing, weaving, up to garment finishing. Together Textile Mills India Private

Limited works on the outsourced orders from THE SHIRT COMPANY INDIA LIMITED.

Today the company boasts of some of the best infrastructure to create and deliver with time

saving deadlines. Together Textile Mills India Private Limited manufacturing shirts only. It

is 100% cotton export oriented company. They have customers in all over the world

especially in European Countries. They don’t have any particular brand name. The brand

name for the product are given according to the design from buyers information.

The company began with the chase of a dream of a world class unit. That would

produce the best quality shirts in India. Mr.Shivanand B Shetty was the man behind the

materialization. To present day Together Textile Mills India Private Limited maintains a high

profile quality regimen to honour commitments to excellence. Entire process of

manufacturing at Together Textile Mills India Private Limited is preplanned and sequenced

for time optimization.

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 An ISO 9001 certified mill with vertically integrated operations right from yarn

dyeing to fabric weaving and fabric finishing.

 Capacity: 1.5 tones of yarn dyeing per day. 2, 50,000 meters of fabric per month.

 In house garments manufacturing unit with a capacity of 45000pcs per month.

 It has all less than one roof life dyeing, weaving, and garments.

 Its running around the clock

 Manpower nearly 500 peoples are working in the concern

 They are manufacturing shirts only.

 This company is 100% cotton export company and they are exporting the goods to all

over the world especially European countries.

 Ro (Reverse Osmosis) based titration facility for removal of save and other

impurities from water to meet most demanding specification that are currently in

place.

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 2.OBJECTIVES OF THE INDUSTRIAL TRAINING

 To gain – full knowledge about the organization.

 To detailed study on each and every department in the organization.

 To know the business dealings of the concern.

 To gain more practical knowledge regarding functioning of the whole organization.

 To study the procedure of maintaining books and records in the concern.

 To know the importance of textile.

 To know the functions of the organization.

 To know the achievement of their goals with in the organization.

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 3.PROFILE OF THE FIRM

Name Together Textile Mills India ( P) Ltd

Address S.F.NO. 460/3B, 461/2A,2B,

Somaiyampalayam Village,

Kanuvai, Coimbatore – 641 108.

Fax 0422-2404400

Status Private limited Company

Date of incorporation 1/1/1997

Area 10 Acres

Managing Director Mr. Shivanand B Shetty

Chief executive Mr. Ashwin Shetty

Executive Mr. Bala Shetty

State of Registration Tamilnadu

Head Office Mumbai,India.

Financial Period April 1ST – March 31ST

Type of Industry Textile (Dyeing, Weaving,Garments)

Business Manufacturing 100% cotton Fabrics (Shirts)

Number of Employees 500

Number of Directors 3

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 Certificate ISO 9001

4.ORGANISATION CHART

Chairman

Chief Executive
Officer

Executive

General Manager

Production
Manager HR Manager Account Manager Environmental
Manager
Dyeing
Personnel Payroll
department department
Environment
Weaving Department
Security
Purchase
department
Garments
Administration

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Supervisors

Labours

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 5.QUALITY POLICY

Our MISSION is to earn the loyalty of all our customers by providing them with

quality garments, which are eco-friendly, competitively priced and have shorter lead times.

We strive to improve our competitiveness by enhancing employee skills, process

performances, and technology utilization while adhering to most stringent quality standards.

Interweaving Social Obligations and Corporate Responsibilities...

Shirt Company takes pride in abiding by all factory laws and WTO Code of Conduct.

Our happy and ever-growing work force is the reflection of our company policies enhancing

human empowerment, meeting ecological concerns and under taking social obligations.

The quality policy is established in line with the organization activities is given

below.

Together Textile Mills India Private Limited will endeavor to manufacture fabrics

and garments conforming to agreed specification at competitive price, to ensure customer

specification through punctually and perfection in our job.

This is achieved by our total dedication accepting quality assurance as our target ,

production of mother nature as our goal and by developing the skills and competence of the

employee.

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 6.VARIOUS DEPARTMENT

1) Purchase department

2) Personnel department

3) Production department

 Dyeing department

 Weaving department

 Garments department

4) Accounts department

5) Environmental department

6) Maintenance and electric department

7) Stores department

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 6.1.PURCHASE DEPARTMENT

The purchase department looks after the requirements of the various departments.

Purchase Department plays the vital role in the organization and arranging the materials for

the required machines. Raw material, machinery spares, stationary items and imported

materials are arranged through the purchase department.

This purchase deals with the purchasing of the Raw materials, Equipments, and Yarns

etc. This department is responsible for any purchase made by the company. Factory manager

is responsible for this department.

Purchase department prepares various documents like purchases order, indents etc.

This department is very important because of company’s profit or loss depends upon it.

Objective Of Purchasing Department:

1. To purchase right materials

2. To purchase material in good qualities

3. To purchase from right and reliable source

4. To purchase materials economically

5. To receive and deliver materials at right place and at right time.

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Activities of the Purchase department:

 Inviting various quotations from the manufacturers and suppliers.

 Verifying and preparing the purchase list as per procedure.

 Checking and maintaining the quality of the item.

 To give purchase order to the supplier.

 Verifying and releasing the purchase order as per the procedure.

 Ledger are maintaining in the purchase department.

Notes of the Purchase department:

 Purchase order note

 Requisition / issue slip note

 Goods receipt note

 Stock register

 Minimum stock level

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Functions of Purchase department:

Purchase indent from concern department

Collection of samples

Asking quotation from suppliers

Quality and price comparison chart

Check the quality

Approval from the authorized person

Send purchase order to the suppliers

Supplying the material distribution to concern department

Payment of bills

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 6.2.PERSONNEL DEPARTMENT

Personnel means managing the workers at the work. The main function of the

Personnel Department activities are to recruit the man power, arrange the shift duties and

maintain attendance register. Also it take care of the Personnel needs of the labour, staff in

connection with production activity.

Personnel Department take care of employees need. It releases the employees from

stress. It gives counseling and solves the employees problems and industrial oriented

problems.

Shift timing in the organization:

Shift I : 7am – 3pm

Shift 2 : 3pm –11pm

Shift 3 : 11pm – 7am

General Shift : 9am – 6am

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Sources of Recruitment:

Once the employee is been selected, he/she will be given a training for a minimum of

3 week and then they will be placed on the job.

Various activities performed by the Personnel Department:

 ESI( Employee State Insurance);

The contribution of employers to ESI is 4.75% and employees to ESI is 1.75%. The

ceiling of ESI is 15000.

 PF( Provident Fund):

It is contributed which is calculated in basic and DA(Direct allowance). The

contribution of employers to PF is 12% and employees to PF is 12%.

Administration charges : 1.63%

 Gratuity:

This is a kind of retirement benefits given by the company to their employees like

provident fund and pension fund. This record maintains the Gratuity of every workers.

Payment of gratuity is mandatory under the factory act.

 House rent allowances(HRA);

The contribution of HRA is 10% of Basic Pay.

 Pension Scheme:

It is the scheme which is same as gratuity an PF. If PF is contributed more than 10

years, Employees are eligible for this scheme.

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The Personnel Department are also involved in the following informations:

 Leave allowances:

A total of 9 days of casual leave and encashment leave of 15 days/annum is allowed.

 Over time wages:

One and half wages for over time duty is given.

 Bonus:

The bonus is been provided based on employees productivity and based on the

attendance.

 Hostel facility:

It is provided for the women workers and there is 130 women employees staying in

hostel. They are provided with free canteen.

 Loans:

Loans to the employees are not allowed. Only advances are allowed in case of

emergencies.

 Transport facilities:

Fuel and vehicle allowances are allowed to staffs who uses their own vehicles. There

are a total of 2 bus and 1 four wheeler are used for employees transport purpose. Free bus

facilities provided for outside lady workers only.

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 6.3.PRODUCTION DEPARTMENT

The primary purpose of production function is to address allocating efficiency in the

use of factor inputs in production and resulting distribution of income to those factors.

Conversion of Raw Material into finished goods is the main function of the Production

Department. The main process of the Production Department are,

 Dyeing

 Weaving

 Garments

Grey yarn is the main Raw material involved in the manufacturing process. This Yarn

is converted by various process and it is made or turn into the finished goods fabric and

finally it is made into many finishing processes and taken as a shirt. Before and after each

process the quality of the yarn and fabric is checked thoroughly. The quality is given most

important after each process.

Production planning incharge and garment incharge in co-ordination with weaving

incharge, processing incharge plans for the production data.

Based on the production planning, Department heads are responsible for identifying,

approving and carrying out the production processes as per customer requirements.

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 Exporting Grey Yarn

Checking & packing Winding

Pre treatment
Washing & Ironing ( Bleaching and
Scouring)

Stitching Re agent
(Fabric to Garments) and Preparation

PROCESS
Pattern Making & Dyeing
Cutting SEQUENCE

Finishing(Stentoring & Finishing

Weaving Hydro-Extractor
(removal of 60%
moisture)

En drawing Radio-Frequency
Dryer
(removal of 40%
moisture)

Warping Winding
(Cheese To Cone)
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 1. DYEING:

 Cheese winding:

This is the process of converting grey yarn from cone form to cheese form to

facilitate dyeing.

The process of imparting the requires colour to textile material like yarn, fabric, etc.

When the raw material (Gray yarn) enter into the company, it’s in the form of tones. Before

the starting process cones is been converted into Cheeses by using cone winding machine.

 Scouring or bleaching process:

This process is used to remove the natural color from the color and impart Quality of

yarn. The whole bleaching process contains 3 to 4 hours.

 Dyeing Process:

Reactive dyes are used in this process. Various size of the machines capacity in the

dyeing department.

 10kg

 20kg

 30kg

 50kg

 100kg

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  300kg (2 machines)

 The dyeing machine made by Weave tex.

 Peroxides, oil and stabilizer and the chemicals are used in the dyeing.

The whole dyeing process contains 4 to 5 hours.

 Washing Process:

Soaps are used for cones and the cheeses (dyed) Softener used to avoid the yarn

breakages, when converting the cheeses into cones.

DRYING:

Drying is done to remove excess moisture from the cheese yarn. This is done through

2 ways.

1. Remove water in Hydro extractor:

This machine used to remove 50% moisture. That means after washing cheeses

contain more moisture.

2. Dry in RF(Radio Frequency)dryer for thorough dyeing:

This dryer used to remove the balance 50% moisture. Hence 18 cheeses are put in

one meter. The total length of this dryer is 3 meter. So we get (3m = 54 cheeses) in one hour.

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Cone winding:

`Dyed yarn is used in the spring cheese form is wound on the cone form in cone

winding machine for further process like warping and pirn winding.

Sectional warping:

It is the process of converting individual yarn into a form of a sheet in which the yarn

is distributed evenly with event tension to facilitate weaving.

 In warping section, first the warping pattern is received from lab.

 The next step in warping is to count the yarns present in the pattern sample from lab 1

per meter.

 By this counting the amount of kilos wanted to produce is ordered (total meters).

 Then the particular kilos of yarn are received from yarn purchase department.

 The yarn purchase department priorly purchases the cones to be readily used.

 The cones are received to produce cloths (reminded).

 The received cones are issued to warping the man who is working in warping is

called “sizers”; they are only to warp the cones.

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 CHART ON WARPING PROCESS

YARN RECEIVED FROM YARN SECTION

YARN ISSUE TO WARPING

DIRECT WARPING

TRANSFER TO SIZING SINGLE COUNT ONLY STARCHED

FINISHED BEAMS ISSUED TO THE DRAWING SECTION

Endrawing:

The process of drawing the yarn through healed wires according to the draft/ drawing

order required for the given design or weave.

Denting:

The process of drawing the warp yarn through Read according to the denting order.

Pirn winding:

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 Transferring yarn from the cone to pirns to use as weft to load in Shuttle.

2. Weaving:

It is the process of interlacing of warp and weft in preplanned manner to form a

fabric.

TWO TYPES OF LOOMS ARE USED.

 Power looms

 Picanal looms

 POWER LOOM

 Make : Krishna, also called lakshmi looms .

 It is semi automatic

 The loom speed – 120 rpm.

 Production capacity 17m per 8 hour.

 Only six frames are used.

 4 colors are used in weft.

 The nadabox is used to decide what colors should be used in sectional time.

 Power loom has no salvage.

 One hp power motor used here.

 Loom cost is in thousands

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 PICANAL (RAPIER) LOOMS

 Its need limited man power , because the loom is automatic.

 Production is high.

 7-10m per hour cloth is produced by using this machine

 This machine uses 8 colors in weft

 This loom contains 20 frames.

 The loom speed is 360rpm

 8weft color is used in the box. That is called preventer.

 In this 8 weaver and one shift supervisor are working.

 Here selvedge cutter used to remove the waste parts.

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SEQUENCE OF WEAVING:

Dyeing

Cone winding

warping

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 Endrawing

Looming

Running Process (fabric check)

Fabric finishing:

 Stenter:

This process is used for maintaining width and length.

 Sanforizing:

This process is used for shrinkage test and dry the fabric.

 Brushing:

It is the process of raising the fibers from fabric.

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  Folding:

It is the process of converting fabric from any other form to metre folding

form.

3. Garment manufacturing:

A process of making readymade garments from fabric.

Pattern making:

Pattern design is approved from merchandiser or corporate office.

Cutting:

It is the process of cutting the fabrics according to the measurement suitable for the

final garment or product.

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Stitching:

It is done to join together, all parts as per requirements to make a full garment or

product.

Button holing:

It is the process of making a cut portion in the required place suitable for buttons to

pass through and the eager are hemmed to avoid fraying if threads.

Buttoning:

Attaching buttons in the right place.

Trimming:

Removal of loose threads, hanging threads, etc….

Pressing or Ironing:

Ironing and Folding of the garment pieces as per the buyer requirement s.

Labeling:

Attaching the require labels or tags in correct place as per the requirement.

Packing:

Packing of folded garments on polybags and putting the packed garments in the

cartons as per requirement.

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Dispatching:

Dispatching the packed cartons as per requirement including, folding of cartons in the

truck.

 The cloths are received from loom shed.

 The produced cloths are neatly folded and the folded cloths are called piece.

 The cloths are checked out.

 If some changeable remarks are there, it should be corrected.

 Washed cloths are recollected and the mistakes are checked out.

 The finished cloths are dispatched to the parties.

Chart On Dispatching Process

Weaved fabric received from loom shed

Rolling Cloth Change To Piece

Meters Counting

Inspection

Damage Fabric Inform To Loom Shed

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 Meters checking

Inspection

dispatch to parties

Make accounts

6.4.ACCOUNTS AND FINANCE DEPARTMENT

The accounts department plays a vital role in every organization. It maintains all the

books of accounts for showing full particulars including quantitative details and situation of

fixed assets.

Here in the company Journal, Purchase Journal, General Ledger, Sales ledger etc.,

accounting are maintained. They also prepare Trial balance, Profit and loss account, Balance

sheet periodically. Then each and every month bank reconciliation statement is prepared by

account assistant to verify whether the cash and bank balances are same.

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  In this organization, all bank dealings are carried out in corporate bank and

vijaya bank.

 Accounting period maintained is Apr 1st to Mar 31st .

 All the accounting procedures are maintained in a computerized manner.

 All financial records is carried out through computerization.

 Central excise duty is exempted sales tax of 12.25%

 The payments are made through cheque which is authorized by chairman.

Accounting record:

Only petty cash book is maintained because the head office is in Mumbai. The

daybook, purchase book, sales books are also maintained.

Auditing:

Auditing is systematic examination of books of accounts and other records such as

invoices, vouchers, etc. which confirms and support the financial status of the firm.

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Types of record:

Periodical auditing is followed quarterly once in a year in this concern. The audit of

books and accounts, are taken up at the end of the financial period; trading account and profit

& loss account and balance sheet is prepared. Auditing is done in one continuous session.

Functions of accounts department:

1. Maintaining the records in an orderly manner

2. Submitting records to the management

3. Checking and passing of bills for payment

4. Checking the lorry receipts

5. Submission of records to the auditor

6. Making payment of wage to the employees

7. Enter the sales invoice and check with the sales department

8. Making advice to bankers and customers

9. Checking the sales journal of the sales department with the invoice received from the

department

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 6.5.ENVIRONMENTAL DEPARTMENT

5.1 Effluent Treatment Plant (ETP):

Together Textile Mills India Private Limited has a total environmental management

plan. Non-hazardous environmental friendly bio-degradable chemicals and dyes are used for

production. Emission control measures are installed to obtain a environment al production

manner.

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Flow chart of ETP:

Effluent from dyeing process

Preliminary treatment
(collection & equalization)

Primary treatment(chemical sedimentation)

Secondary treatment(Biological treatment)

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 Tertiary treatment
(adding sodium hypho-chloride & aluminium sulphade)

Advanced technology(reverse osmosis)

Permeate water Reject water

Permeate water Reject water

Salt recovery
(Reuse for dyeing process )
5.2 Sewage Treatment Plant (STP):

Sewage ids generated from the canteen and domestic purposed used water. The
canteen is the major contributor of waste and it is operated. The mill has a well equipped
sewage treatment system to treat the sewage waste water. After the treatment system, the
treated sewage can be used for gardening and irrigation of agricultural purpose.

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Flow chart of STP:

Effluent from canteen and toilet waste

Bar screen chamber

Oil and grease removal chamber

Collection tank

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 Submerged fixed film Bio-reactor

Tube setter

Clarified sewage tank

Pressure sand filter

Treated sewage water for

6.6.STORES DEPARTMENT

Material and suppliers are the important assets of any business enterprises.

CHART ON STORES DEPARTMENT

STORES DEPARTMENT

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 STORE KEEPER

STORE CLERK STORE ASSISTANT

WORKERS

For the stores department there is one storekeeper, who is responsible for maintaining the

stores items. He will keep the records for the movement of items, i.e., Documents such a

requisition, Purchase orders, Intents, Receipts, Issues etc. are maintained along with stock

layer.

On the receipt of invoice received from the suppliers, they are verified with the

physical quantity received. On the receipt of the material. The storekeeper will make the

receipt entry approval of the item to account department for accounting and payment

purpose.

FUNCTIONS OF STORES DEPARTMENT

1. To receive Materials, Goods and Equipments and to check for identification.

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 2. To receive parts and components which have been processed in the factory.

3. To record the receipt of goods.

4. To correct positioning of all material in the stores.

5. To issue items to only on the receipt of the authorized stores requisition.

6. To record and to have a updated receipt all time and issue of materials.

7. To check the bin card balances with the physical quantities in the bins.

8. To make sure that stores are kept clean and maintained with sufficient soap for the

goods ordered.

7. LABORATORY

 Converting gray yarns to finished goods contain many process and stages.

 The material is checked at many stages whether it is a quality one or not.

Laboratory contains many testing machine, they are as follows.

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Appearance tester:

 It is also called ASDM (American Standard Machine).

 Here we check the raw material (Gray yarn) strength. 1m = 17 mistakes

(mismatch) allowed. Otherwise total gray yarn is cancelled

Twist tester:

 This tester used to find how many twists are in the yarn.

 Make-State

Yarn Strength Checking:

 This machine used for checking the strength (Putting 120 yard yarn in the

machine & know the strength) by using.

BMW:

 This machine used for checking how much of chemical needed to get the

color which buyer specifies.

Washing machine:

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  Made by IFB

 After getting the fabric from the weaving department, fabric shrinkages are

checked by sanforizing machine.

Color matching machine:

 According to the light which buyer uses (requirement) in their shop , the

fabric and dyeing yarn are checked.

Rubbing Testing machine:

 Fix the white width on the machine fabric and it is pressed and checked

whether fabric shade is got or not.

 If it make any shade in the fabric, that is corrected by the Grayer machine.

8.CONCLUSION

The industrial training had given me an immense pleasure to study Together Textile

Mills India Private Limited, the various department activities on it.

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 The industrial training on shirt manufacturing concern helped me to gain practical

knowledge and risk involving in it.

I really extend my thanks to the manager, accountants and assistants, supervisor,

employees. Especially to the General Manager who allowed me to under go this training in

this concern. It was very usefully to me. I got more information form the official of the

concern about various process and technical development prevailing in the modern industries

especially in the concern.

This training helps me to know the project the partial working of textile unit other.

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