CHAPTER – I

INTRODUCTION

The Textile Industry

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

A cotton mill is a building housing spinning or weaving machinery for the production
of yarn or cloth from cotton an important product during the Industrial Revolution in the
development of the factory system.

Although some were driven by animal power, most early mills were built in rural areas at
fast-flowing rivers and streams using water wheels for power. The development of
viable steam engines by Bolton and Watt from 1781 led to the growth of larger, steam-
powered mills allowing them to be concentrated in urban mill towns, like Manchester, which
with neighbouring Salford had more than 50 mills by 1802.

The mechanisation of the spinning process in the early factories was instrumental in the
growth of the machine tool industry, enabling the construction of larger cotton mills. Limited
companies were developed to construct mills, and the trading floors of the cotton exchange in
Manchester, created a vast commercial city. Mills generated employment, brought economic

1
growth to the area and even provided town residents with educational and leisure
opportunities. Drawing workers from largely rural areas and expanding urban populations.
They provided incomes for girls and women. Child labour was used in the mills, and the
factory system led to organised labour. Poor conditions became the subject of exposés, and in
England, the Factory Acts were written to regulate them.

Before the Industrial Revolution, textiles were produced according to a small-scale putting-
out system. Under this system, merchants contracted out work to ordinary women and even
children to produce textiles in their own homes. Articles of clothing were then sold by
merchants to the general public at markets and other retail venues . Spinning mills were
introduced to the United States in 1790 by English-born mechanist and businessman Samuel
Slater (1768–1835). The twenty-one year old had worked as a textile labourer for more than
six years in an English mill, where he learned about the workings of a cotton-spinning
machine invented (1783) by Richard Arkwright (1732–92). The British considered the
Arkwright mill the cornerstone of their booming textile industry and laws prevented anyone
with knowledge of the mill from leaving the country.

CHAPTER - II
2
 ORGANISATION PROFILE

The Company
At Rajapalayam, in South India, 132kms away from Tuticorin Harbour is one of
India's best yarn producers S.A. Aanandan Spinning Mills spread over across 7 acres
of land, with most modern spinning facilities of 30,000 spindles and plans to double
the capacity near future. They venture into manufacture of innovative products like
Linen/cotton blends with counts 14s to 30s and multiple plied yarns till 20 PLYS in
our newly installed machines.

They also have a subsidiary made ups, Ananda Fabrics which produces shop towels,
kitchen towels, bar mops, terry towels besides other home textiles in 100% Cotton and
Polyester/Cotton blends, exclusively for USA market.

S.A.Aanandan Spinning Mills (P) Ltd – a unit of S.A.Aanandan Group was

incorporated in the year 1997-98 and since then it has been producing high-class
cotton and Linen - Cotton blended. Yarns for both export and domestic markets.

Yarn made from Cotton: Count Range: 2s to 120s - For Weaving, Knitting, Sewing,
Tea Bag Thread etc., in Single/ Double/ Multiple ply, Carded, Combed, Elite compact,
Elitwist (Siro),Digital Slub, Gassed, Mercerised, Gassed Mercerised, Bleached and
Dyed Cotton Types.

Mission

To provide quality products to customers and explore new markets to

promote/expand sales of the company through good governance and foster a sound and
dynamic team, so as to achieve optimum prices of products of the company for
sustainable and equitable growth and prosperity of the company.

Vision

To attain customer satisfaction by delivering nothing but the best, by means of utilizing the
highest quality of resources and world-class systems.

Achievements

3
 S.A.Aanandan Spinning Mills (P) Ltd., has won the following Export Award for the
year 2014-2015 from The Cotton Textiles Export Promotion Council – TEXPROCIL
sponsored by Government of India.

Objectives

 To achieve overall quality improvement of the products of textile industry by

providing testing (including eco-parameters) and technical services.

 To enhance overall skill levels through Integrated Skill Development Scheme

(ISDS).

 To estimate the domestic consumption of textiles in the household sector.

Corporate and social responsibility

 Ethical, Environmental and Social responsibility

They follow ethical and environmental practices in our production units. We do Rain
Water harvesting to preserve water. They plant and grow trees to keep campus
atmosphere / ecosystem intact. Managing sewage by proper collection and allowing to
decompose through bacterial activity before draining by means of a soak away. They
do not have effluent to treat. Smoking strictly prohibited inside factory area and No
Plastic bags of low Micron allowed. They follow amiable policy on Health, Safety and
Wellbeing and Welfare of all employees to keep them fit to carry on there duties well.
They give special attention to our Social responsibility to take care of all our
employees equally well outside also.

 Policy on child labour

They don’t recruit trainees below 18 years of age and age proof insisted to ascertain
the same for employment. DISCRIMINATION POLICY: While recruiting, training,
retaining and promoting we do not discriminate on the basis of Religion, Caste,
Gender, Language and physical disability. They always aim to value merit, hard work,
sincerity and loyalty of all our employees.

4
  Policy on compensation

While All workers are paid wages either higher than minimum wages prescribed by
Government of India or Government of TamilNadu. If they have to work overtime,
they will be compensated separately in accordance with national rules.

Products

Cotton

Our latest production range is 100% Cotton: 2s to 120s - For Weaving, Knitting,
Sewing, Tea Bag Thread etc., in Single/ Double/ Multiple plied yarns. They also
produce 100% cotton hank yarn in varying counts from 5S to 100S. Their yarn
standsfirm in hank market for its own compromising quality, grade and strength
parameters. Yarn Types: Carded, Combed, Elite compact, Siro Spun, Digital Slub,
Ring doubled / TFO Twisted, Gassed, Mercerised, Gassed Mercerised, Bleached and
Dyed.

5
Linen / Cotton Blended yarn

In order to diversify and be innovative, they started to find new products other than
the conventional 100% Cotton yarn. They found that there is a shift in consumer
preference towards Cotton Blends with other Natural Fibres such as Linen, Ramie,
Hemp etc. They also noticed the fashion trend is more towards Linen / Cotton and
hence decided to produce Cottonized Linen blends using Cotton. They have partnered
with Aditya Birla – Grasim Group - EUROPEAN FLAX® CERTIFIED COMPANY
for transferring knowhow and technology for supplying Cottonized Linen Fibre, the
successful production of Linen blends and marketing of the same.

Moreover they have Technical skill and ability to utilise available machinery to
produce the Linen/Cotton Blended yarn which very few Mills in India can only take
up.

Organisational chart

6
 PURCHASE
MANAGER

PURCHASE
DEPARTMENT STORE KEEPER

PRODUCTION
PRODUCTON MANAGEER
DEPARTMENT

WORKERS

DOMESTIC CLERK
MARKETING
DEPARTMENT

EXPORT CLERK
MANAGING GENERAL
DIRECTOR MANAGER
SALES DEPARTMENT SALES MANAGER

WORKERS

STORES PURCHASE CLERK

DEPARTMENT

STOCK CLERK
ACCOUNTS
DEPARTMENT
ACCOUNTANT

QUALITY CONTROL
DEPARTMENT SUPERVISOR

7
 CHAPTER - III

DEPARTMENTS AND THEIR FUNCTIONS

The main objectives of the departments in the company are, understanding the functions of
different departments in the spinning industry, and identifying the various equipment used in
the company.

The various departments are,

1. Purchase Department

2. Production Department

3. Quality analysis Department

4. Marketing Department

5. Sales Department

6. Stores Department

7. Accounts and Finance Department

8. Human resource Department

1. PURCHASE DEPARTMENT

The first function of textile mill is purchasing raw materials. Raw materials include the
purchase of cotton. Before the purchase, samples of cotton are received after checking it the
purchase order is made.

The purchase is done through the brokers, commission agents, or through the direct dealing
of the spinning mills. They purchase cotton as bale wise.

8
 The purchasing department is similar to the sourcing department but the main difference is
that the sourcing department works for sourcing the fabrics alone while the purchasing
department works for sourcing the accessories and trims. However, the working procedure is
the same. The working is as follows.

After the order is being confirmed by the buyer the merchandiser will sit with the other
concerned departments and then the exact quantity required and the breakup of the trims and
accessories with respect to colour, size, etc., will be given by the merchandiser to the
purchasing department in the form of a sheet which is generally followed in the industry for
all the orders irrespective of the buyer. Once the purchasing department receives this format,
then the purchase order is sent to the concerned department for accessories and trims. Once
the first shot of the raw materials is sent by the supplier then the lab dips are done and are
approved by the buyer.

After receiving the goods from the supplier they a rechecked for the quantity and also
checked according to the inspection criteria specified by the buyer and replaced if any of
them are not meeting this criterion. This department also keeps track of all the quantities
received in-house timely. The goods are generally received in breakups as suggested by the
merchandiser according to the requirements stated by the planning and the production
department and this breakup will have specified date and quantity and if this breakup is not
being mentioned then the order is being placed with the supplier several times for small
quantities and purchase orders have to be sent all the time so, in order to overcome this a
breakups are being is given.

Then the purchasing department has to follow up with the supplier for deliveries as and
when the merchandiser asks for the new set of the materials for that particular style and then
the department also has to maintain the receipts and also they have to maintain the documents
of the inspections that are being carried out for those materials.

Functions of purchase department

 The purchasing department is to procure all necessary materials needed for production
or daily operation of the company or government organization.

 It is also charged with continuously evaluating whether it is receiving these materials

at the best possible price in order to maximize profitability.

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 This organization maintains six kinds of Subsidiary books. They are Cash book, Purchase
book, Purchase Return book, Sales book; Sales return book, and Journal proper. They
maintain a separate book for purchases and purchase returns. The Purchase book or Purchase
day book contains the record of all credit-purchase. Cash book accommodates the records of
all goods-purchase. The purchase book does not hold the entries for purchase of assets; it
includes only the details of the bales of cotton they purchase.

The entries in the purchase book are recorded with the help of source documents. The
invoice or bills from the supplier serve as the source document. Only the net amount is entered
in the purchase book that it does not contain trade discount. Every month the total of purchase
book is posted on the debit side of the purchase account.

When the goods purchased on credit are returned to the supplier, these are recorded in the
Purchase return book. Sometimes, goods purchased can be defective or of low quality, etc. and
hence, need to be returned. A separate book is maintained for the purchase return and these are
not deducted from the purchases in the Purchase book. Also, Purchase return is recorded at the
net amount on the invoice. Debit note is prepared for every return of goods. It is prepared in
duplicate. The original one is sent to the supplier while the duplicate copy is kept for our own
records. These are the functions and the books maintained in the purchase department.

Purchase record

1.Basic samples collection.

2.Offer samples test result note.

3.Purchase confirmation register.

4.Vendor evaluation record.

1.Basic samples collection

The basic sample collection record contains the details about sample that is purchased
before making the actual purchase. The sample of cotton is received from various companies
10
and the specific variety which suits the company in manufacturing the yarn is selected. This
basic sample collection contains the details about the company from which the sample is
purchased and the quantity is also mentioned.

2.Offer samples test result note

This offer sample test result note contains the details about the result in the test made in the
sample cotton purchased. This includes the variety of cotton whether it is organic or hybrid.

3.Purchase confirmation register

Purchase confirmation register is a buyer generated document specifying the quantity of

bale of cotton and the variety of cotton. It also includes the price for which the purchase is
made.

4.Vendor evaluation record

This note keeps the record of the performance of the supplier, the performance of the
supplier include the quality they supply and their financial background also. Once the specific
supplier is approved he may be re-evaluated on a periodic basis

Flow of control
PURCHASE MANAGER

PURCHASE ASSISTANT

STORE KEEPER

11
 2. PRODUCTION DEPARTMENT
Before the actual production process is started the trail production is held for
confirming the requirements of the customer. This is been tested in the quality control
department and necessary changes are made as per the requirement. The production
manager is responsible for maintaining the production plan and he controls it with the
coordination of all the department personnel. This production department is
responsible for the production of yarn. The various processes in Production are,

MIXING

BLOW-ROOM

CARDING

COMBER

DRAWING

SIMPLEX

WINDING

a) Mixing Process

This is the first process which is carried out manually by labours. Various types
of cotton which have staple length of required standard suitable for the count of yarn
to be spun are mixed on a floor depending on the capacity and the requirement of the
plant and the production for the day. In mixing 1%to 2% soft waste is added to the
virgin cotton. Mixing enables the technicians to reduce the raw material cost for
particular yarn. Mixing enables technicians to mix superior and inferior cotton in a
certain proportion as required in the market of the yarn. Therefore in a spinning mill

12
mixing is a vital process which enables raw material cost reduction as well as to keep
cotton lint with same moisture content. Mixing also enables the cotton lint to open up
easily in the blow-room and carding process. This is done to reduce the micro dust
pollution in the departments. Micro dust and small fibre are the main components
which cause thick and thin places in yarn. To achieve better evenness in yarn the
departmental pollution of short fibres should be reduced to minimum. After mixing the
mixed cotton is carried to blow-room.

b) Blow-Room Process

It is the first department where the cotton is subjected to machines. It is called

blow-room because the process of material takes place with the help of air currents.
The material is blown from machine to machine through the pipeline. It is where the
fibre is opened; cleaned, mixed, micro dust removed and evened this passed to carding
machine without increasing fibre rupture, broken seed particles and without removing
more good fibres. The basic functions of blow-room are opening, cleaning and dust
removal, blending and evenly feeding the material on the card.

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Functions of Blow - Room

1.Opening

Opening is the first operation it means, tearing apart the compressed and matted
cotton until it is very much loosened and separated into small tufts with a gentle
treatment, and a fibre loss as small as possible.

2.Cleaning

Cotton contains up to 18% trash in most cases. To clean the material it is

unavoidable to remove as much fibre as much waste. Therefore it is necessary to
measure the amount of the waste removed and its composition. As it is of high
importance also called cleaning efficiency. The cleaning efficiency always has to be
optimized and not maximized, since the fibre quality (short fibres,) as well as fibre
loss is always negatively affected by maximum trash removal.

3.Dust removal

To extract the contamination in the cotton such as leaf, stone, iron particles, jute,
poly propylene, coloured fibres, feather and other foreign material from cotton by
opening and beating. An often underestimated task of the blow room line is the
removal of dust. However, it is as important as the removal of impurities. De-dusting
in the blow room happens by air suctioning only, either between the machines.

4.Blending\Mixing

It is meant as the intermingling of different kinds of fibres or different grade of

same fibres e.g. polyester & cotton, Viscose & cotton. Blending of fibre material is an
essential preliminary in the production of a yarn. Fibres can be blended at various
stages of the process. These possibilities should always be fully exploited. However,
the starting process is one of the most important stages for blending, since the
components are still separate and therefore can be metered exactly and without
dependence upon random effects.

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 c) Carding Process

Carding is the second process in spinning. The quality of yarn entirely depends on the
carding effect on the fibres that are spun into yarn. Carding is a mechanical process that
disentangles, cleans and inter-mixes fibres to produce a continuous web or sliver suitable for
subsequent processing. This is achieved by passing the fibres between differentially moving
surfaces covered with card clothing. It breaks up locks and unorganized clumps of fibre and
then aligns the individual fibres to be parallel with each other.

From the carding machine depending on the type of yarn to be produced different processes
take place. For carded yarns the material is directly sent to Drawing process to draw-frame
machines. For combed yarns the process is lengthy with inclusion of sliver lap, ribbon lap,
super lap and combing processes before going to Draw-frame machines. This combing
process is done to yarns which are sent to manufacture hosiery fabrics by knitting processes.

For the carded yarns, the material from carding is directly fed into draw-frame machines.
Now considering the process for combed yarns, from carding the sliver is fed to sliver lap
machine. In sliver lap machine 6 to 8 slivers are fed from the creel stand to main machine
which contains condensing rollers which condense these slivers into a single band of sliver
lap.

The combing process is normally used to produce smoother, finer, stronger and more
uniform yarns. Therefore, combing is commonly confined to high grade, long staple natural
fibres. To improve the yarn quality, the comber must perform the following operations:

 Elimination of precisely pre-determined quantity of short fibres;

 Elimination of the remaining impurities;
 Elimination of a large proportion (not all) of the neps in the fibre material;
 Formation of a sliver having maximum possible evenness;
 Producing of more straight and parallel fibres.

Elimination of short fibres produces an improvement mainly in staple length, but also affects
the fineness of the raw material. The micron ire value of combed sliver is slightly higher than
that of feedstock (elimination of dead fibres).

d) Comber Process
15
 The raw material delivered by the card is unsuitable for combing both as regards form and
fibre arrangement. If card slivers were fed to the comber, then true nipping by the nipping
plates would occur only on the high points, with the risk that the nippers could not retain the
less strongly compressed edge zones of the slivers. These could then be pulled out as clumps
by the cylinder combs. A sheet with greatest possible degree of evenness is therefore required
as in feed to the comber.

A good parallel disposition of fibres within the sheet is a further prerequisite. If the fibres
lie across the strand, even long fibres are presented to the cylinder combs as if they were
short fibres and they are eliminated as such. This represents unnecessary loss of good fibres.

A combing machine is a one type spinning machine for spinning process of yarn which has
comb to straighten the fibres and extract neps, foreign matter and short fibres. Combing
machine is used to produce higher count yarn(stronger , more even, more compact, finer,
smother). The yarn which is produced by using combing machine is called combed yarn. This
machine produces finer yarn by removing short fibres below a pre-preselected length. It
reduces length variation in the cotton mixing for yarn market. It removes neps and foreign
matter form the cotton. This machine improves fibre parallelization and straightens of the
fibres from spinning wool.

e) Drawing Process

Carded Slivers are fed into the Draw-Frame and are stretched/ Straightened and made in to
a single sliver. Also fibre blending can be done at this stage. The cans that contain the sliver
are placed along the draw-frame feeder rack, usually including eight pairs of cylinders (each
pair is above the space occupied by a can), the lower cylinder is commanded positively, while
the upper one rests on the lower one in order to ensure movement of the relative sliver that
runs between the two.

Functions of drawing process

 Drafting
 Equalizing
 Parallelizing
 Blending
 Dust removal

16
 Within the sequence of m/c in cotton spinning mill, the draw-frame is the definitive
compensation point for elimination errors. Inadequacies in the product leaving the draw-
frame not only pass into the yarn, they are actually reinforced by drafting effects following
the draw frame. The yarn is never better than the draw frame sliver.

At drawing stage, material passes not only one m/c but usually 2, arranged 1 after the other
& combined to form a group. Processing in 2 passages is necessary completely to fulfill the
requirements. The 2nd passage is often superfluous after combing m/c because then it does
not normally generate any improvement in quality. As discussed the drawing process of
slivers is done in two stages namely breaker and finisher. The drafting zone of draw-frame
machines contain three metallic rollers which are called as bottom rollers and three top rollers
with a synthetic rubber coating compressed by pneumatic pressure. The hank of the sliver
here at the finisher draw-frames is maintained between 0.140 to 0.150.

f) Simplex Frame Process

The roving/Simplex frame is an intermediate machine between draw frame and ring frame
the main objective of this machine is to convert sliver into thinner sliver for the convenience
of subsequent processes. The sliver we obtain from draw frame is still thicker sliver which is
not good for yarn manufacture. So the sliver thickness or the yarn count is reduced by this
machine to the required level. But in this operation main drawback is that the reduction is
somewhat so high and cannot be obtained from roller drafting mechanisms. The solution for
this is to reduce the yarn count into a low level but not to the level required to the yarn
manufacture which means the production of intermediate sliver which is called roving sliver.

Objectives of speed frame

 Attenuation of draw sliver to a suitable size for spinning.

 To insert a small amount of twist to strengthen the roving.
 To wind the twisted strand roving into a bobbin.

 Ring Spinning Process

17
 The Ring Spinning is the most widely used form of spinning machine due to significant
advantages in comparison with the new spinning processes. The ring spinning machine is
used in the textile industry to simultaneously twist staple fibres into yarn and then wind it
onto bobbins for storage. The yarn loop rotating rapidly about a fixed axis generates a surface
referred to as "balloon". Ring frame settings are chosen to reduce yarn hairiness and the risk
of glazing or melting the fibre.

The ring spinning frame, commonly called the ring, is the conventional spinning system
and it transforms the roving from the roving frame into spun yarn using the operations of:

 Drawing
 Twisting
 Winding

In the last step of yarn production, the staple fibres are fed to the ring spinning frame, after
passing through the blow room (opening and cleaning) and the carding frame, drawing frame
and flyer (separation of individual fibres, parallelization, formation of a fibre tape). Here, the
finished yarn is produced by drawing and rotating operations.

Objectives of Ring Spinning

 To draft the roving fed to the ring spinning frame i,e to convert roving intovery fine
strand called yarn.
 To impart strength to the yarn by inserting the necessary amount of twist.
 To collect twisted strand called yarn onto handy and transportable package by
winding the twisted thread on a cylindrical bobbin or tube.

g) Winding Process

The cop which is prepared in the ring frame is not suitable for further processing. So the
yarn is converted into the shape of cone which is prepared in the winding. Practical
experience shows that winding process alters the yarn structure. The factors which affect the
yarn structure during winding are bobbin geometry, bobbin unwinding behaviour, binding
speed. This phenomenon does not affect the evenness of the yarn but it affects the properties
of the yarn such as thick places, thin places.

18
 After manufacturing of yarn, from different departments in the preparatory process and
ring department, it is ready to make a shape into final cone form so that it can be shipped to
customer for use. During winding process of yarn following objectives are met.

 Scanning and faults removing Electric Scanners (uster) are used for checking and
elimination of yarn faults during winding process. This process is called Usterization
of yarn. Such faults are called scan-cuts.
 Splicing of broken or cut yarn Auto splicing is done for broken yarn pieces to
eliminate yarn knots and bad piecing.
 Bigger package Conversion of yarn from small ring bobbins to bigger yarn cones of
different international standard or as per requirement of customer.

During achieving above objectives or making of winding cones some faults are created
during the process. These faults need to be controlled through monitoring and continuous
study. Most of the winding faults are very dangerous for the next subsequent process which
can be warping or knitting or doubling. We can face complains from customer of breakage of
yarn during unwinding process.

 Auto Corner Process

Yarn package winding is the completion of the yarn forming process and the starting point
for various subsequent processes, from weaving or knitting to textile finishing. This interface
function of winding is what makes the winding process so important. In winding, the course
is set for high cost-effectiveness in the following stages of the textile production chain. At the
same time, care is taken that the quality of the yarn wound will meet the demands placed on it
by the finished articles. Textile- technological know-how crucial in this context is elaborated
in cooperation with world-leading partners in textile machine engineering.

Typical features of the Auto corner performances are: extensive textile-technological

expertise, consequent market and customer orientation, early recognition of changes in
market conditions and requirements, and excellent customer advice and training service all
over the world. These have contributed to the world-wide success of the Auto coner, from the
first to the present generation. Translating this now-how into intelligent winding machine
technology has made Schlafhorst for decades the innovation leader in the international arena.
The whole spinning activity ends with winding process.

Waste management
19
 The some amount of waste is discharged at every stage of production. In order to
optimize productivity, cost and quality it is always necessary to maintain at a particular level
which in turn depends upon the cotton. Hard waste include all the waste that comes from the
process such as spinning, cone winding, etc., which cannot be reused but can be sold out.

Flow of control
PRODUCTION MANAGER

PRODUCTION
SUPERVISOR

WORKERS

3. QUALITY ANALYSIS DEPARTMENT

A firm belief in the fact that quality is the key to success, this company empowers
its units with almost all aspects of delivering nothing but the best in quality.

The in-house R&D wing with state-of-the art instruments works round the clock to
ensure quality parameters with the objective of delivering only the top most Quality
output.

The in-depth understanding of the involved processes has also helped the mill to
expand its presence in Indian as well as overseas market and keep pace with the fast-
changing global yarn demands.

While the mill strives to improve its productivity and expand the capacity on gradual
basis, the mill has quality progress as below, ISP 9001 - Quality systems to provide
necessary conceptual and structural input for fulfilling customer needs by ensuring
consistent and desired product quality.

20
 The employees have been trained to adopt new technology, standard work
practices like 5s, Quality Circle, TQM, TPM etc. The mill believes their employees to
be their valuable assets and regularly sharpens their skills by imparting training to
meet global standards of quality.

Quality is a measurement system cover the entire organisation from sales through
shipping. It is a procedure or set of procedure intended to ensure that a manufactured product
or performed service adheres to a defined set of quality criteria or meets the requirements of
the client or customer. This quality analysis department prepare a weekly report and is
submitted to factory manager and is forwarded and signed by the General Manager.

Inspection and Testing

The inspector takes the study daily in all the departments. They check the quality of the
product at each point. The report is submitted to the factory manager and the supervisor.

Reports given by quality control department

 Daily production statement signed by managing director

 Daily yarn quality statement
 Daily electrical statement
 Delivery inspection report

Types of test

1.Yarn twist

2.Linear density

3.Yarn strength

4.Yarn elongation

5.Yarn evenness

6.Yarn hairiness

1.Yarn twist

Twist is defined as the spiral disposition of the components of yarn, which is generally
expressed as the number of turns per unit length of yarn, it is essential to keep the component

21
fibres together in a yarn. The increase in twist, the yarn strength increases first, reaches a
maximum and then decreases.

2.Linear density

The fineness of the yarn is usually expressed in terms of its linear density or count. There
are a number of systems and units for expressing yarn fineness. For the determination of the
count of yarn, it is necessary to determine the weight of a known length of the yarn. For
taking out known lengths of yarns, a wrap-reel is used. The length of yarn reeled off depends
upon the count system used. The increase in the count shows the decrease in the density of
the yarn and the decrease in the count shows the increase in the density.

3.Yarn strength and elongation

During routine testing, both the breaking load and extension of yarn at break are usually
recorded for assessing the yarn quality. An important factor which affects the test results is
the length of the specimen actually used for carrying out the test. The strength of a test
specimen is limited by that of the weakest link in it. If the test specimen is longer it is likely
to contain more weak spots, than a shorter test specimen. Hence the test results will be
different for different test lengths due to the weak spots.

4.Yarn hairiness
It is a complex concept, which generally cannot be completely defined by a single figure.
The effect of yarn hairiness on the textile operations following spinning, especially weaving
and
knitting, and its influence on the characteristics of the product obtained and on some fabric
faults has led to the introduction of measurement of hairiness. The yarns produced with
condensers in the drafting field, particularly if these are situated in the principal drafting
zone, are less hairy than those spun without the use of condensers. The increase in hairiness
due to spindle eccentricity, will be influenced by the diameter of ring, diameter of bobbin, the
shape of the traveller, the yarn tension, etc.

Flow of control

QUALITY CONTROL
DEPARTMENT
22
 SUPERVISOR

4. MARKETING DEPARTMENT

Marketing is a human activity directed at satisfying needs and wants through an exchange
process. The aim of marketing is to make sales in orders to earn reasonable profit for the
producer.

Marketing has an intensive position in today’s business activities. Marketing of products

helps in gaining popular and profits easily.

 To market the products enquiry is the important first steps and to enquiry received
from enquiry for the products of quality, price.
 For parties’ interest, instruction sent to weaving section to finish the goods within
time period given so performer invoice is used for getting payment.
 This will enable the concern to quite competitive rates in the market moreover
information for conforming the sale of the products.

4-p’s of marketing

PRODUCT -2s to 120s yarn

PRICE -cost of material + cost of labour + profit margin

PLACE - Rajapalayam

PROMOTION - Direct marketing

Functions of marketing department

 The agents helps the company to market their product in foreign countries.
 They find the market through their agents.

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  Sales are made based on the orders received.
 Company gives their agents offers.
 The agent acts as a indirect sales representative.
 The exports are done according to procedures laid by the central government.

Flow of control

MARKETING
DEPARTMENT

MARKETING DOMESTIC MARKETING EXPORT

CLERK CLERK

5. SALES DEPARTMENT

Production of goods is done for sales. Sales means transfer of goods from one person to
another in the course of business for cash, deferred payment or valuable consideration. The
effectiveness of sales in the organisation is the most important factor for the progress of the
firm, because the final result depends on the efficiency of the department.

To maintain its customer base, sales department takes responsibility for making sure
buyers are happy, as well as trying to up sell them. The division is proactive in contacting
customers with surveys and special offers and is reactive in attempting to solve any problems
that might cause the company to lose customers.

Objectives of sales department

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  Converting Sales & Customer Acquisition

The sales department’s main objective would be to make sales. That said, making sales is not
the only objective. The main goal is to make sales as efficiently and inexpensively as
possible. They also shorten their sales cycle.

 Retaining Existing Customers

Retaining existing customer is as important as customer acquisition. It is less expensive,

easier and of course a lot less time-taking. Customer retention is an integral part of a sales
department which must not be overlooked at any cost.

Different Roles in the Sales Department

Although the basic mission of a sales department is to organize data and generate deep
customer insight in order to enhance sales force productivity and effectiveness, the practical
roles within a sales department vary widely. Basically, the teams choose to offer varying
levels of service depending on sales organizations sophistication.

 Sales Force Representative

The sales force representative takes care of the first step of the sales funnel. Their main tasks
include Sales Development, Sales Training, and Sales Force Communications Management.
Here the responsibility of sales force representative is Connecting the sales teams to the most
relevant content for each opportunity in the buying cycle. Communicating updates like
content alerts, product news to the sales force and also
empowering managers and peers to coach in a way that reinforces training as well as
promotes best practices.

 Account Executive

Here in this company the account executive brings in new business and closes the final sales
deal. The executive create presentations, demonstrate the sales plan in a more elaborate
manner, write proposals, and negotiate the final terms with the client, and eventually, close

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the final deal. The account executive’s primary objective is helping businesses
implement technology solutions in a cost-effective way by determining the requirements of a
project or program and communicating them clearly to stakeholders, facilitators as well as
partners.

 Sales Administration

The executive of the sales administration has in-depth knowledge of their business and the
business domain. Whenever the sales force representative or account executive gets stuck
with something, its the sales administrator who takes over and solves the problems. The
executive is also involved in looking over at the tasks performed by sales representatives and
designating sales target to them. They are in charge of all the employees working in the sales
department.
They have to delegate sales target and other such duties to the people working in the
department.
The sales administrator has to study the market condition regarding the company’s products.

 Customer Success Planner

The executive makes sure that the customer is happy and satisfied with the sales, and then
accordingly works on following up and retaining them.Create communication forums to
address off-cycle problems and close gaps to plan.
The duties may also include providing support for financial inventory analysis, the
creation of an annual operating plan, and special projects as needed to support cross-
functional initiatives.

 Sales Operations Manager

A sales operations manager is the Chief of Staff to the Sales Organization, the person who
leads the team and oversees every other function performed in the sales department. This
person is responsible for making sure the team is working in sync to achieve the targeted

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goals and meeting their responsibilities. From measuring the performance to calculating the
gains, this person makes the final decisions and reports.

Flow of control
SALES MANAGER

SALES AGENT

WORKERS

6. STORES DEPARTMENT

Most of the company failures are due to locking up of huge amount of funds in stock.
Either over stocking or under stock both are not worthwhile to a company. Hence
maintenance of optimal stock does not result in shortage of working capital.
Storekeeper has to maintain complete list of raw material and peripheral suppliers along
with their price list to contact them immediately during emergency circumstances.
Storekeeper has to decide the minimum and maximum quantity of materials to be stored in
the godown. Further the storekeeper should place orders based on the requisition made by the
concerned departmental heads and based on the reorder level as he maintains placed orders
with the supplier of raw material and other peripheral suppliers under no circumstance the
storekeeper should not allow the raw material to go below the danger level.
After receiving the goods it is the duty of the store keeper to ascertain or verify that the
goods received are match with the specification mentioned. If there is any deviation the
storekeeper should receive the explanations for the same from the supplier else if the
explanations are not satisfactory then the storekeeper should return the goods once again to
the supplier. This company follows the FIFO method.

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Storekeeper Functions
 The store keeper is in charge for all the goods which is under his control.
 Store keeper has to maintain all records relating to materials inward and materials
outward.

In ordinary purchase the store keeper knows about the scarcity of material in the store and he
places order for those materials. Where as in emergency purchase for materials like wheels
becomes important and they have to purchase immediately this comes under the emergency
purchase. The store keeper after receiving the intent of the spinning supervisors approach the
parties and purchase those materials.
No materials is in warded and taken out without the consent of the storekeeper. On the receipt
of material the store keeper maintain a material inward note. If the supervisor asks any
material the store keepers issue it and enter in the material issue slip.

Flow of control
STORES DEPARTMENT

PURCHASE CLERK STOCK CLERK

Procedure of issue of material

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 Purchase requisition

3rd party quotation

Quotation approval

Purchase order

Goods receipt note

Stores recognition

Stores issue

7. ACCOUNTS DEPARTMENT

Accounts are the important of any company. The accounts department provides
authorization and control to all other subsystem to utilize money more effectively through a
well designed mechanism.

Accounts department is headed by the Finance Manager and his team of efficient
accountants. They maintain record for each and every transaction relating to business. All the
financial decisions taken are reviewed by the managing director before being put into action.

This department is in charge of all the tax computation involved with any local purchase and
sales made. They also take care of handling the company’s tax processing and provide proper
accounting documents such as profit and loss account, balance sheet to the auditing
authorities on demand.

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 The financial year of the company starts from 1 st April and ends31st March every year. The
accounts department also computes the weekly wages and monthly salaries for the employees
of the company.

Functions of accounts department

 Collection filling of all vouchers and bill receipts.

 Handling bank transactions.
 Handling debtors and creditors transactions.
 Preparing periodical documents to analyse business growth.
 Wages salary computations.

Role of Cashier

 For the cash from the various sources.

 Credit – voucher is prepared to show income.
 Debit – through cash payment voucher.
 Various departments prepare voucher and when that voucher is bought to the cashier,
cash is delivered there and then cashier prepares cashbook and daybook.
 The person who makes expenses prepares cash payment voucher and is submits the
same to the cashier. The same amount is given to him.

Accounts classification

 Audit fees.
 Bank charges.
 Bank.
 Canteen maintenance.
 EB lighting charges.
 Factory maintenance.
 Electrical repairs.
 Provident fund collection and payment.

Flow of control

ACCOUNTS
DEPARTMENT

ACCOUNTANT

CLERK
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 8. HUMAN RESOURCE DEPARTMENT

The human resource department is responsible on those aspects which are primarily
concerned with the relationship of management employees and with development of the
individual and group.

S.A.AANANDAN SPINNING MILLS has exceptionally established the way of harmony

with the employees. Fair and fabulous working environment enable the workers to do their
work more enthusiastically. Monthly and weekly wages are available based on their
preference.

Training of workers

Training is done in a very excellent manner as a huge percentage of workers are the
apprentices, the human resource manager just gives instruction to the workers and the
supervisors give the training.

Recruitment

Recruitment is by direct approach of the workers or direct visit to the work place and the
contract agency also helps the mill for recruiting. They are paid with the commission for the
same.

The company follows various recruitment procedure, they are

1.Recruitment

2.Interview

3.Selection

4.Orientation

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 1.Recruitment

The recruitment process starts with the approval of the director of the company. The
recruitment is done when there is resignation, hr planning, death, retirement, etc., when there
is a vacant in a specific department the head of that specific department must submit a letter
to the human resource department specifying the recruitment for the specific designation, job
description, skills required, education required. After the approval of the vacancy and the
approval from the human resource department the recruitment process starts. The sources of
recruitment are advertisement through print media, job posting on company notice board.

2.Interview

Before the interview stage begins the CV’s of the applicants both hard copy and soft copy are
being collected. Once the CV’s are collected the short listing the candidate process begins.
The short list is totally based on the qualification, educational qualification, and work
experience. The qualified CV’s are stored and also sent to the manager who further shortlisted
the CV’s according to the skills required for the job. The candidates are called for the
interview. Set of questions are asked to the candidate which include general knowledge, team
spirits, leadership quality, confidence level, etc.,

3.Selection

After the completion of the interview process, the selection is done based on the performance
of the candidate in the interview and their CV’s, the shortlisted candidates’ background are
verified thoroughly before the appointment. The offer letter is sent to the selected candidates
through email and hard copy is also sent if needed, and the rejected candidates are also
informed through the regret letter, and their data is stored for the future use.

4.Orientation

During the orientation stage the selected employee is told about the rules and regulation of
the company and he is also taken on a walk through all the departments. His duties are also
being explained and to whom he is accountable. He is also told about the communication
level. The employee is also given training in specific department.

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 Office time

SHIFT SHIFT TIME HOURS

1st shift Day shift 7.30a.m. to 3.30p.m. 8
2nd shift Half night shift 3.30p.m to 11.30.p.m 8
3rd shift Full night shift 11.30p.m. to 7.30p.m. 8

Employee State Insurance

ESI benefit is given to permanent workers. It is a self financing social security and health
insurance scheme for Indian workers. This fund is managed by the employee’s State
Insurance Corporation according to rules and regulations stipulated there in the ESI act1948.

Provident Fund (PF)

It is a form social safety net into which workers must contribute a percentage from their
salary and the company also contribute a percentage as PF to their workers.

CHAPTER – IV

SUMMARY OF WORK DONE

DAY DATE WORK DONE

Learnt the general introduction of the company, date of

1 13-05-19
commencement.

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 Learnt the procedure in purchase of raw material and their
2 14-05-19
uses.

Visited stores department and gained knowledge about the

3 15-05-19
functions of this department

4 16-05-19 Gained knowledge about the

Gained knowledge about the various steps in the

5 17-05-19
manufacturing of yarn.

Gained knowledge about the maintenance of store ledger

6 18-05-19
and the procedure for issue.

Learnt about the recruitment process followed in the hr

7 20-05-19
department.

8 21-05-19 Learnt the marketing methods in the marketing department.

9 22-05-19 Learnt the preparation of debit and credit voucher.

Learnt about the various test carried in the quality analysis

10 23-05-19
department.

11 24-05-19 Entered the details of the employees in the computer.

Learnt the preparation of bills and the various types of bills

12 25-05-19
in the accounts department.
Learnt the maintenance of books of accounts in sales
13 27-05-19
department.

Learnt the preparation of sales ledger in the accounts

14 28-05-19
department.

15 29-05-19 Learnt the preparation of attendance for the employees.

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 Learnt the working of finance department and their
16 30-05-19
functions.

17 31-05-19 Learnt the preparation of journal books.

Learnt the process in purchase of material and the books

18 01-06-19
maintained in the purchase department.

Learnt the preparation of purchase ledger and the entries in

19 03-06-19
the books.

20 04-06-19 Gained knowledge about the GST filing.

Learnt the preparation of profit and loss account and balance

21 06-06-19
sheet.

22 07-06-19 Learnt the preparation of cash flow statement.

23 08-06-19 Learnt the preparation of debit and credit vouchers.

24 10-06-19 Learnt the preparation of pay roll and the calculation of PF.

CHAPTER – V

CONCLUSION

During the period of my training in S.A.AANNADAN SPINNING MILLS, I have learnt a lot
of functional aspects of various department the purchase, production, accounts department
etc., I have also trained with the flow and delegation of authorities from the top level to
middle and lower level management.

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The Industrial training has provided a valuable knowledge on various functions of different
departments the harmonious and the efficiency of staff and employees were quite normal.

The training enables me to have a correct view of the various practical aspects and difficulties
of the various theoretical are immensely benefited from training program.

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