Report Sip
Report Sip
Report Sip
On
"Morarjee Textile,Nagpur"
By
"Amit Rewatkar"
Submitted to
I, the undersigned Amit Rewatkar , declare that the Project Report title as,
“To Study the production process and production system”, submitted by me for partial
of the project work carried out by me during the period from 25 July 2018 to 25 Aug 2018 ,
under the guidance of Dr.Punamkumar Hinge internal guide and the same has not formed the
basis for the award of any degree, diploma, association, fellowship, titles – in or for any other
education in Management.
At the start, I would like to express my sincere gratitude to Dr.Punamkumar Hinge my project
guide from SIBMT, Pune – 411021 for successful completion of a project in partial fulfillment
of Master of Business Administration (M.B.A.) under his able guidance to allow me to work on
such an interesting subject. He provided me proper and correct direction for completion of
project work. His continuous guidance during the course of project helped me in channelizing
my efforts, quite appropriately.
I am also thankful to Shewta Bodkhe , Morarjee Textile , for guidance given and cooperation
extended for carrying out the project.
I am also thankful to all the respondents and friends who have helped me to conclude the
contents of the project in decent and presentable manner.
Research Methodology
ANNEXURES
Executive summary
This study presents an interactive model based system for the management of production in textile production
systems focusing on the process. Because of the special characteristics of the industry, that is mainly the multi
process with multiple units per phase, different planning horizons and different production requirements for
each phase, the scheduling of these systems becomes quite complex. Apart from a comprehensive presentation
of the set of production system is composed of many operations together with their interrelationships, the
capacity, workforce, quality of product characteristics and analyzed, and their impact on the production control
system is explained. The system is also related to two well-known production control systems, and Optimized
Production Technology. The system’s attributes are presented with the aid of data structure diagrams, while the
complete algorithm concerning the module, in a pseudo-code form, and the corresponding part of the database
are illustrated in the Appendix.
CHAPTER 1
Introduction
The Indian textile industry is one of the oldest industries in the country and displays a very complex sector
dispersal matrix with hand-spun and hand-woven sector on one end of the spectrum and the capital-intensive
sophisticated mill sector at the other, with the decentralized power loom and knitting sectors coming in between.
Even in the organized sector, “island of excellence” exist, using highly sophisticated information technology
based equipment with facilities for ERP/SAP which are second to none in the world.
The fibre specific configuration of the textile industry includes almost all types of textile fibres from natural
fibres like cotton, jute, silk and wool to synthetic/man-made fibres like polyester, viscose, nylon, acrylic,
polypropylene and the multiple blends of such fibres and filament yarns.
The diverse structure of the industry coupled with its close linkage with our ancient culture and tradition
provides it with the unique capacity to produce, with the help of latest technological inputs and design
capability, a wide variety of products suitable to the varying consumer tastes and preferences, both within the
country and overseas.
It is perhaps the only industry in the Indian industrial arena which is self reliant and complete in value chain, i.e.
from raw material to the highest value added products, i.e. garments/made-ups.
Textile industry is one of the few basic industries, which is characterised as a necessary component of
human life. One may classify it as a more glamorous industry, but whatever it is, it provides with the basic
requirement called clothes. There are numerous kinds of fibres and other raw materials, which are used to
produce a cloth. This paper provides an insight about the basics of textiles and the terms that are used all around
the world in context of textile industry. Regarding study of textile fabrics, meaning of the word textile must be
made quite clear. The dictionary states that the word is derived from the Latin word texerel to weave, but a
wider meaning of weaving must be accepted since it is one of the various ways to produce textile fabrics. The
initial stage of textile manufacturing involves the production of the raw material either by farmers who raise
cotton, sheep,silkworms, or flax or by chemists who produce fibre from various basic substances by chemical
processes. The fibre is spun into yarn, which is then converted into fabric in a weaving or knitting mill. After
dyeing and finishing, the woven material is ready for delivery either directly to manufacturer of textile products
where they are finally stitched into clothes.
Objective of study
Scope of study
Literature Review
The Indian textile industry has a significant presence in the Indian economy as well as in the international textile
economy. Its contribution to the Indian economy is manifested in terms of its contribution to the industrial
production, employment generation and foreign exchange earnings.
It provides direct employment to about 35 million persons including substantial segments of disadvantaged
sections0. of the society and women. Besides, another 50 million people are engaged in allied and ancillary
activities. The industry has been growing at a steady rate of 9-10 percent. In the post quota period, the industry
size has expanded from US$ 37 billion in 2012-15 to US$ 49 billion in 2015-18. In this period, while the
domestic market increased from US$ 23 billion to US$ 30 billion, exports increased from around US$ 14 billion
to US$ 19 billion. Being one of the largest of its kind in the world, the Indian textiles industry has inherent
strengths that have the potential to increase its share substantially in the global trade of textiles and clothing.
Strengths of the Indian Textile sector
India is one of the few countries that encompass the entire supply chain in close proximity, from diverse fibres
to a large market. It is capable of delivering packaged products to customers comprising a variety of fibres,
diverse count sizes, cloth of different weight and weave, and variety of finishes. One unique feature is of its
being extremely varied, with the hand-spun and hand-woven sector at one end of the spectrum, and the capital
intensive, sophisticated mill sector at the other. The decentralized hand looms / hosiery and knitting sectors
form the largest section of the textiles sector. The close linkage of the textile industry to agriculture and the
ancient culture and traditions of the country make the Indian textiles sector unique when compared to the
textiles industry of other countries.
Major Sectors of the Textiles Industry
1. Organized Cotton / Man-made Fibre Textiles Mill Industry: It is the largest manufacturing industry in
the country in terms of employment with nearly 1 million workers and number of units. There are more
than 1818 cotton / man-made fibre textiles mills (non-Small Scale Industry), with an installed capacity
of 35.37 million spindles and 0.45 million rotors. The production of spun yarn stood at 3791 million kg
during 2016-17.
2. Man-made Fibre / Filament Yarn Industry: The industry comprises fibre and filament yarn
manufacturing units of cellulose and non-cellulose origin. The total man-made fibre production from
April-August 2016, increased by 16 percent, as compared to the corresponding period of the previous
year. The total production of man-made filament yarn increased by 11 percent during 2016-17.
3. Decentralized Power-looms Sector: The decentralized power-looms sector plays a pivotal role in
meeting the clothing needs of the country. The power-looms industry produces a wide variety of cloth,
both grays as well as processed. There are over 1.95 million power-looms in the country that provide
employment to nearly 4.86 million workers.
Chapter 3
Industry
The textile industry is primarily concerned with the design, production and distribution
of yarn, cloth and clothing. The raw material may be natural or synthetic using products of the chemical
industry. Cotton is the world's most important natural fibre. In the year 2007, the global yield was 25 million tons from 35
million hectares cultivated in more than 50 countries. There are five stages:
The largest exporters of textiles in 2013 were China ($274 billion), India ($40 billion), Italy ($36
billion), Germany ($35 billion), Bangladesh ($28 billion) and Pakistan ($27 Billion).
In 2016, the largest apparel exporting nations were China ($161 billion), Bangladesh ($28 billion), Vietnam ($25
billion), India ($18 billion), Hong Kong ($16 billion), Turkey ($15 billion) and Indonesia ($7 billion)
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
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.
China 274
India 40
Italy 36
Germany 35
Bangladesh 28
Industry and Company Profile
www.morarjee.com
Unit -2 (2003)
Unit -3 (2016)
The data has been gathered through interaction and discussions with the executives working
in the division. Some important information has been gathered through couple of
unstructured interviews of executive. Annual reports and other magazines published by the
company are used for collecting the required information.
PRIMARY DATA
The primary data of m y project is collected from all department of textile industry. In the
textile industry the main work is done by the textile manufacturing and export procedures
and all the operations in textile industry. The data collected by interview, survey, discussion
SECONDARY DATA
The secondary Data of company is collected to know the advance technology of the textile
industry and this will happens it becomes more beneficiary and reliable to the economic
condition. The information is collected from Magazines, Newspapers, Internet and websites
etc.
Sample size
The sample size 30 from where the date is collected from every department of the textile
industry.
Data Analysis
Spinning unit
Spinning is the twisting together of drawn -out strands of fibers to form yarn, and is a major
part of the textile industry. The yarn is then used to create textiles, which are then used to
make clothing and many other product s.
1. Step: Blow room operation here, the compressed bales of fibers is opened for making the cotton tuft in a
small size. Cleaning: This operation is used to remove dust, dirt, broken leafs, broken seeds, stalks and
other foreign materials from the fibers.
2. Step Carding process here the fibers must be disentangles, and it gets straightened. The straightening
process puts the fibers into parallel direction and the sliver is formed.
3. Step: Draw frame breaker here the draw-frame feeder rack, usually including eight pairs sliver the relative
sliver that runs between the two. Rieter - E 35 OMEGA lap machine is used for this operation which
doubles the sliver to sliver.
4. Step: Comber here the sliver is feed to the combing machine to get very fine and straight sliver.
5. Step: Draw frame breaker in this process the 6 sliver get converted into 1 sliver
6. Step: Speed frame In this process the sliver is converted into roving get twisted and bind on small cone.
7. Step: Ring Frame In this process the small robin is converted into thread bind on the bigger cone.
WINDING
↓
WARPING
↓
SIZING
↓
DRAWING
↓
LOOMING
↓
WEAVING
2. Warping
Warping is the process of transferring a number of yarns from a creel of single end packages, forming a
parallel sheet on to a beam. The main objectives of warping are:
To get the required number of ends as per set calculation.
To get the required length of yarn on each beam of the set.
To wind a specific type of package required by subsequent process.
3. Sizing
The weaving requires warp yarn to be strong, smooth and elastic to a certain degree. To achieve these
properties, protective coating of a film forming agent is applied to the warp yarns prior to weaving. The
application of size material on the warp sheet, to induce the desired properties is called slashing or sizing. Sizing
is to produce Quality Fabric economically and efficiently.
The chemical used for sizing to increase the strength Asap cone ,SFR, Phenol, count (70),M-plast (80)
Fig5.1 Toyota JAT 810 loom machine
Production machine
Grey loom: 32 loom
Capacity produce: 9000 MTR/Day
Dyed loom: 80 loom
Capacity Produce: 33000 MTR/Day
Grey fabric
Bleaching
Dyeing Finishing
Printing
Finishing
Folding
Chemical consumption
1. Peroxide -150kg/Month
2. Hypo Chloride -500 Kg/Month
3. Cotoclarina 63 -50 Kg/Month
4. Forylase AT -50 Kg/Month
5. Ran Sc -50 Kg/Month
6. Nockel -70kg/Month
7. Mega Acid -60 Kg/Month
8. Mega Tube ACA -40 Kg/Month
Processing Department
Scouring
Scouring is the first process carried out with or without chemicals, at room temperature or at suitable higher
temperatures with the addition of suitable wetting agents, alkali and so on. Scouring removes all the waxes,
pectin’s and makes the textile material hydrophilic or water absorbent.
Bleaching
Bleaching, a process of whitening fabric by removal of natural color, such as the tan of linen, is usually
carried out by means of chemicals selected according to the chemical composition of the fiber.CBR, Jet
Drying, Kier, Jigger Machine are used for bleaching process.
Steamer
Temperature
Fortracta 23 95oC 95oC 95oC 95oC
Steamer
After that the fabric goes to the steamer which is located at a higher level where direct heating is given to the
fabric. Only steam is present in the streamer. The temperature of the steamer is usually 94`C. The fabric stays in
the steamer for 10 minute. On the sides of steamers there are four tanks having hydro caustic after A-Ring. Here
the fabric loss the strength and remove impurities.
Dyeing
1. Creation-The design is created and designed according to the specifications given by the customer. The
people from marketing department visit the place and understand about the design that needs to be printed
according to the specifications provided by the buyer.
The design to be printed is decided by:-
specifications given by the buyer
Trend forecasting
Fashion forecasting
Magazines report
2. Separation: The colors present in the specific design are made in several specific channels. The color
components present in the design are segregated individually to understand the color requirement according to
that design. It is decided by the printing department, design studio, PPC, marketing and quality control. The
process of separation is done on the basis of availability of machines & the design specifications given by the
buyer. The finalized design is then sent for engraving or exposing.
3. Engraving or exposing: This is the process of engraving the specified design on the screens so that it can be
used for printing processes.
Process flow of exposing:
Unpacking the screen
Degreasing
4. Strike Off
The order or design specifications are given by the buyer to the marketing department and the design
studio.
Ingredients used for printing is sodium alginate ,urea (10-15 %) ,sodium bicarbonate ,Turkey Red oil
(TRO ) and water (80 % ).
10 -15 made samples are sent to the buyer for approval out of which5-7 samples are selected for bulk
printing.
This process takes a time span of 10 days for the completion of whole process.
Printing
It is done either with flat or cylindrical screens made of silk threads, nylon, polyester, vinyon or metal. The
printing paste or dye is poured on the screen and forced through its unblocked areas onto the fabric. Based on
the type of the screen used, it is known as 'Flat Screen Printing' or 'Rotary Screen Printing.
A significant characteristic of screen printing is that a greater thickness of the color can be applied
to the substrate than is possible with other printing techniques. This allows for some very interesting effects that
are not possible using other printing methods. Because of the simplicity of the application process, a wider
range of inks and dyes are available for use in screen printing than for use in any other printing process.
Utilization of screen printing presses has begun to increase because production rates have
improved. This has been a result of the development of the automated and rotary screen printing press,
improved dryers, and U.V. curable ink. The major chemicals used include screen emulsions, inks, and solvents,
surfactants, caustics and oxidizers used in screen reclamation.
Screen printing is by far the most common technology today. Based on the type of the screen used. Two types
exist:
1) Rotary screen printing
2) Flat (bed) screen printing
.
Rotary Screen Printing
Rotary screen printing is so named because it uses a cylindrical screen that rotates in a fixed position rather
than a flat screen that is raised and lowered over the same print location. Rotary presses place the squeegee
within the screen. These machines are designed for roll-to-roll printing on fabric ranging from narrow to
wide-format textiles. In rotary printing, the fabric travels at a consistent speed. By converting the screen-
printing process from semi continuous to continuous, higher production speeds are obtained than in flat bed
printing. Typical speeds are from 50-120 yards per minute for rotary screen printing depending upon design
complexity and fabric construction.
Zimmer machine is used for the process.
Engraving is done on the screen.
Zimmer have 12 screen colors.
After printing Ageing 102 C is done for reactive color and for pigment color curing done at 150 C.
Printing capacity is 30000 meter at 6 mpm to 100 mpm .
Then the fabric is send to the quality check and then to the finishing Department.
Fig. 8.1 Rotary screen machine
Plate and Frame Printing
In Plate and frame screen printing, this process is an automated version of the older hand operated silk screen
printing. For each color in the print design, a separate screen must be constructed or engraved. If the design has
four colors, then four separate screens must be engraved. The flat-bed screen process is a semi-continuous, start-
stop operation. Flat screen machines are used today mostly in printing terry towels. Currently, approximately
15-18% of printed fabric production worldwide is done on flat-bed screen machines.
Printing process a where the Plate and frame is used for printing .
Screen design is engraved the by the machine.
Then it is send to the printing machine where different design screen is used to print on the fabric
6.3.2 Sanforising
It is pre shrinking finishing
Shrinkage > 5 %
Speed 50 m/min
After shrinking zone, there is a setting zone to set the shrinkage in fabric
Pressure-9kg/cm2
Finishing types
1. Soft finishing
2. Stiff finishing
3. ETI finishing
4. Anti Micro Bacterial
6.4 Folding
Grey Fabric Inspection occurs in fabric inspection for the weaving/ spinning defects. The removable defects are
removed and noted down, and irremovable defects’location is noted down and the frequency is noted. There is a
roller attatched counter which counts the number of metres inspected and helps in location the position of the
defect.
Findings
Spinning Department
Preparatory Department
Winding and Warping process take place to soft cone and to warp on beam
Sizing operation is done where chemical is used to increase the strength of beam warp yarn
Chemical used in sizing are SFR,MPlast, Fanol (70-80) count ,Scote for 100 count .
Weaving Department
Weaving Department installed capacity 112 looms.
Weaving production department had 32 dyed yarns and 80 grey yarn.
Per day production target 33000 MTR/day for 80 looms grey yarns.
Per day production target of 9000 MTR/day 32 looms dyed yarns.
Machine used for Loom Toyota -810
Processing Department
Continuous Bleaching Reactor CBR is used for bleaching the grey yarn loom
Mercerization Process provide smoothness to the loom per day cap 75000
Technology absorption:-
(i) The efforts – made towards technology absorption
• Latest Generation Biological ETP 1400 KLD and RO of 92 % water recovery is installed.
(ii) The benefit derived as a result of above efforts.
• Improvement in quality and productivity.
• Cost reduction
• Energy conservation.
Total capacity of plant
Global supplier
Company has 30% domestic export and 70 % to the gulf and Europeans countries.
Quality
Company work under 5s quality circle .Quality circle is used which regularly to identify, analyze and
solve work-related problems
TPM –Total productive maintenance, kaizen, lean, Six Sigma are used in the industry.
Certification: ISO 9001-2000
ISO 14001-2004
Morarjee Textile having the good human resource. The entire employees in the company are well
trained and qualified in to the work. All the departments are well established and fulfill the need of the
The company is doing well in the market but have to improve the quality of the product. The machinery
used in production is updated. If company will improve in the all mentioned sector the sell of the
company will increase and the company will achieve the top rank in the competition.
Morarjee textile is one of the leading cotton fabric and textile products companies in India. This
company produces fabrics. This company has the large share of the market. It is having more turn over
The company Morarjee textile have the main competitors are not the Indian there are also the
multinational companies.
The Morarjee textile in Nagpur is mainly produces the fabrics. The production is done on the basics of
market requirement.
Chapter 7
Recommendation & Suggestion
1) Morarjee Textile should develop managerial skill particularly to identify the weaker section to reach the
2) Morarjee Textile must play prominent role in financing which may result in rising level of income and
employment.
3) The present official staff of Morarjee can be given a suitable management training that modern
management concept and management technologies can be vitalized in the day to day business for the further
improvement.
Chapter 8
Limitations of the study & Scope for further research
Limitation
There are some limitations of the study.
Time constraint is a big factor here. Because it takes lot of time to make the report more effective and
suitable for everyone. Moreover, data availability is another big issue here because company does not
want to disclose all the confidential information regarding sales and profits
Bibliography
1. www.morarjee.com
2. Annual report MTL
3.http://admin.umt.edu.pk/Media/Site/STD/FileManager/OsamaArticle/january/jan26/Textile%20Fibre%20to%
20Fabric%20Processing.pdf
4.http://admin.umt.edu.pk/Media/Site/STD/FileManager/OsamaArticle/january/jan26/Textile%20Fibre%20to%
20Fabric%20Processing.pdf
5. Manufacturing processes in the textile industry. Expert Systems for fabrics production J. Bullón Péreza, A.
González Arrietab, A. Hernández Encinasc, and A. Queiruga-Diosc
6. Production planning and control in textile industry: A case study
7. Lean manufacturing practices in textile industries –a case study
P.G. Saleeshya* and P. Raghuram
Questionnaires