elite fabs deva.ms
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1.2 EXPANSION OF THE TEXTILE INDUSTRY
There are three sectors in the textile industry mill sector, and handloom sector. The
latter two are jointly considered under the heading described sector. Over the years, the
government has granted many concessions and incentives to the decentralized sector with the
result that the share of this sector in total production was 76 percent in 1950-51, it feel 38
percent in 1980-81 and further to 3.7 percent in 2001-2002. The share in 1950-51 to 96.3
percent in 2001-02. The share of the entire mill sector was only 1946 million square meters
the rest 40488 million square meters being contributed by the decentralized sector.
The two sub sectors handloom and power looms in the decentralized sector, it is the
power looms sub sector that has grown at a faster pace. For instance, in 2001-2002, the share
of power looms.
In total fabric production was large as 76.8 percent while hand looms contributed 18
percent. There are many reasons for the past development of the power loom sub sector:
i. Governments favorable policies on synthetic fabric industry.ii. Ability of this sub sector to introduce flexibility in the product mix in line with the
market situation;
iii. Low labor costs achieved indirectly through the flexible use of labor itselfresulting in lower cost of production, and providing an edge in the market; and
iv. Increase in exports from the power loom sub sector.
Now they are 13 lakh looms in different regions with concentration in Maharashtra,
Gujarat and parts of Uttar Pradesh. Only lately power looms complexes have been spinning
up in Tamil Nadu and other states. There are about 6.5 million employees working in the
power loom sector. As noted above, hand loom, sub sector now accounts for about 18 percent
total production of fabric. This sub sector provides employment to about 3 million weavers
in households and 12.4 million in complexes or total of 15.4 million.
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With aim of developing the three sectors of the industry via, mills, power looms and
hand loom in an integrated manner; the government announced a new textile policy in June
1985. The main objective of this policy was to enable the industry to increase of cloth of
good quality at the reasonable prices for the vast population of the country as well as for the
export purpose. The textile modernization fund of Rs. 750 crore was created 1986 to meet
the modernization requirements of the industry. A textile worker workers rehabilitation fund
has been set up to provide interim relief to workers rendered unemployment as a consequence
of permanent closure of textile rendered. Another measure of significant importance has
been the deli censing of the textile industry as per the textile order 1993. Under the new
policy prior approval of the government is not necessary to set up textile mills including
power looms.
As a result of all these policy initiatives, the textile industry has been growing steadily
in recent years with the organized sector concentrating mainly on the manufacture of fabrics
for exports and also production if denim or fabrics in great demand in the domestic as well as
overseas markets. The increases in quantities of yarn required by all sectors are being
provided by the spinning mills while many composite mills had also there spinning sections.
Purely spinning mills have been springing up in different states with many large size
units being promoted for catering exclusively to overseas buyers. There has been almost on
Unconscious Division of work amongst the different industry. The organized sector is
concentrating on high quality fabrics intended for exports and also fabric base on systematic
fibers, the power looms sector is growing phenomenally in stature while the hand loom
weavers are turning out products with special designs.
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1.3.3. OUTDATED PLANT AND MACHINERY
Since the cotton textile industry is fairly old in India and number of mills was set up
long back, the machinery and equipment have grown old and outdated and need fast
replacement. Production with the help of such out dated and machinery results in higher
costs and poor quality of product. However, attempts at modernization and replacement of
old machinery by new machinery are hindered on the one hand by the capital/financial
constraints facing many units and on the other hand, by protest from the labour.
Modernization in world automation which is likely to displaces labour. For instance,
according to one estimate, single worker can over see 48 automatic looms. The problem is
aggravated by the fact that due to stagnant demand conditions, there is little possibility of the
displaced labour being employed elsewhere in sector.
1.3.4. LABOUR PROBLEMS
The cotton textile industry has been faced with frequent labour problems. In 1982 the
industry was rocked by a labour strike in Bombay which continued for eight months. While
some problems of labour are genuine it is not do Elite Fabs true that the cotton textile have
become the playground for personal rivalries and the testing ground for some political
groups.
1.3.5. SICKNESS AND RECESSION IN THE MILL SECTION
The textile industry is plagued with the problem of demand recession, financial
crunch, spiraling costs and heavy duty imports. In additional persistent and continued uses of
old plant and machinery has led to low profits and profitability in the mill sector forcing some
of these mills to close down.
1.3.6. COST FACTORS
India is the largest producer of cotton yarn and fourth largest producer of cotton. As
the world demand for cotton yarn is increasing, India is well poised to increase its exports forcotton yarn significantly in years to come. However, much export for cotton yarn
significantly in years to come. However, much will depend on the cost factors i.e. whether
India will be able to complete successfully with China, Pakistan, Taiwan, Brazil, and other
cotton yarn exporting countries as for as cost of production is concerned.
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Compared with China and Pakistan, Indian salaries and wages are higher by 30 to 60
percent making it imperative for Indian mills to maintain a high labour productivity to be
competing. It is also estimated that Indian spinners pay 100-150 percent more than
production cost as against 5-7 percent of the competitions. The cotton cost accounts for
almost 65 percent of cost of production. Therefore it is necessary that mills plan their cotton
purchases at competitive prices.
1.3.7 NATIONAL TEXTILE POLICY, 2002
The national textile policy was announced on November 2, 2002 the basic objectives
of which is to take care of challenges and opportunities presented by the changing global
environment to the domestic textile industry, specially initiation of the process of gradual
phasing out quantitative restrictions on imports and the lowering of tariff levels for
integration of the world textile and clothing markets by end 2004. The strategic thrust areas
identified by the policy are technology up gradation, product diversification, and increase in
exports innovative marketing strategies, financing arrangements, maximizing employment
opportunities and integrated human development.
Among the highlights of the policy are a proposal for setting up of a venture capital
fund for trapping knowledge based entrepreneurs of the industry, extension of the technology
up- gradation fund scheme to all manufacturing segments of the industry and the de-
reservation of the garment sector.
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2.0 COMPANY PROFILE
We introduce ourselves as M/r. Elite Fabs, one of the leading knitwear manufacturer
and exporter from Tirupur, India.
Spread over an area of 55,000 square feet of workspace, backed by the best workforce theindustry can provide and with the vertically integrated setup like Knitting, Dyeing, Printing,
Compacting and Garment Sewing, the company is capable of producing 10,000 pieces of
basic T-shirts, 7000 pieces of Fashion styles and 4000 pieces of Hi-fashion styles per day.
Product range includes basic Jersey Garments to fashion styles such as Reps, Velour,
Fleece, Auto Stripers etc. We are certified forISO 9001:2000 (U.K)
We serve for the major brands in the UK and Europe directly and through importers.
Quality and the nature of the fabric is based on the knitting machines, therefore we
have equipped world renowned knitting machines. The possible fabrics types are Single
Jersey / Pique / Semi jacquard / Interlock / Engineering Strips / Full Jacquard / Wraper Etc.
We use the latest soft flow dyeing machines which maintain a consistent shade
throughout the fabric. We keep production environment clean and hygienic. We use dyes that
are free of ago-dyes, agreeable to the regulations passed against forbidden dyes in Germany.
Shrinkage control or compacting is a mechanical shrinkage control process which is achieved
by the compacting machine imported from TUBE-TEX-USA.
The fabric, cut fabric, semi stitched, fully stitched are embroidered according to
pattern. Be it logo, chest and label, they can be embroidered in the in-house Embroidery
machine imported from Japan.
Cutting Room is handled both manually (for stripes, Jacquards to get the stripes and design
set in side seam) and also mechanically, i.e., Lay cutting of KM cloth by a cutting master to
make consistent and sharp cuts.
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2.1 EXPORT MANAGEMENT
2.1.1 GARMENTS AND ITS IMPORTANCE
In this context, we find that garment industry has become a dynamic growth area inexports, and it will be worthwhile to well a little on its growth and prospects.
The garments industry in India has developed mainly through export efforts. The
exports which were of the order of Rs. 12 crores in 1970-71 have increased to Rs. 4012
crores in 1990-91 and Rs. 8112 crores in 1993 94. Indian garments are being exported to
various parts of the world. Yet our share in the world trade in clothing is less than 2%. To
understanding this phenomenon it would be necessary to comprehend the international setting
in which trade in textiles and clothing takes place.
International trade in textiles and clothing has been regulated since 1974 under the
aegis of the multi rearrangement. An important provision in the MFA is the provision for
regulating exports through bilateral textile pacts between the exporting and importing
countries.
India has bilateral trade agreements with USA, EEC, Austria, Sweden, Norway, Finland and
Canada under the multi fiber arrangement.
The bulk of Indias exports of garments is to the countries with which India has
entered into bilateral agreements under MFA. The Indian readymade garments industry has
much advantage over its counterparts in other countries. It fits neatly into Indian economic
scene, as it consists of a large number of its in the small scale and cottage industries sector.
And is consequently labour intensive providing employment to millions of workers. Its basic
raw material, namely, fabric, comes mostly from the decentralized power loom sector which
in turn sustains a large number of weavers.
In the coming years the garment industry, given the vast labour force in the country
and the country and the cotton edge, can expand its export base.
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2.2 PRODUCTS & FINISHES
A.PRODUCTS
The following are the customers of Elite Fabs.
Charles Vogle Trading AG, Desigual, Super Confex, Western Stores, Tom Tailor, XOXO Jennyfer Bizzbee
It offers the following products
Mens t-shirt/outerwear Ladies t-shirt. outer wear Kids wear Nightwear Mens, Ladies and Kids We are an all round player rather than focusing on single product line. This gives us the flexibility for the future growth.
B. FINISHES
We can do special finishes like
Garment pigment dyed
Different enzyme washes Peaching Tie & dye, Dip dye Brushed Acid Wash
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FABRICS & Printing Range
C. FABRICS
We offer Products in variety of fabric range classified in general as follows:-
Single Jersey Knits Pique Knits Rib Knits single, double, flat back Inter lock Jacquards, Pointal, Stripes Flat Back Rib Two / Three Thread Fleece (Brushed & Non Brushed) French Terry (Brushed & Non Brushed) Lycra Jersey [All feeders] Polar Fleece (Single & Double side) Waffle Knit Cotton/modal and cotton/polyester blends
D. Printing Range
We have a tie-up with printing factory where we can do all type of print
Plastisol prints Foam prints Motif prints Flock prints Pigment prints Transfer prints Discharge Print Reactive Print Gel Print
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2.3 INFRASTRUCTURE - Garments Division
Sl. No Machine Type No. of Machines
1 4 Thread Over Locking Machines 28
2 Twin Needle Flat Locking Machines 13
3 Single Needle Power 32
4 Cutting Machine 2
5 Ironing Tables/Vacum Bed 6
6 Button Stitching Machine 1
7 Stain Removing Machine 2
8 Genset 30 KVA 1
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INFRASTRUCTURE
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2.3.1 INFRASTRUCTURE - Knitting Division
Sl. No Machine Type Make No. of
M/c
1 20&24 Gauge/24
Dia/72 feeder
PAILUNG 1
2 20&24 Gauge/26
Dia/78 feeder
PAILUNG 1
3 20&24 Gauge/30
Dia/90 feeder
PAILUNG 1
4 24&28 Gauge/32
Dia/96 feeder
PAILUNG 1
5 24&28 Gauge/34
Dia/102 feeder
PAILUNG 1
6 20&28 Gauge/24
Dia/44 feeder Auto
Stripe
ORIZIO 1
Production capacity: around 3 tons/day
We can do all type of jerseys, auto stripes, feeder stripes, engineered stripes, Selfdesigns (variations of jersey knit like, pique, French terry etc.,) with and without leas
than.
2.3.2 INFRASTRUCTURE Fabric Processing Division
We have a fabric dyeing facility with a production capacity of 3.5 tons/day. We havemachines with capacity ranging from 1200 kg till 100 kg to have the flexibility of
dyeing big quantities and small quantities as well. In addition to this we have
machines to do 50 kg & 25 kg for sampling purpose.
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We have separate bleaching facility to make white fabrics with the productioncapacity of 2.0 tons/day.
All are imported machines to give good quality fabric
2.4 Collection Ladies
2.5 Collection Men
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2.6 VARIOUS TEAMS OF ELITE FABS
Managing Partners are closely involved in the day-to-day activities and ably supported by the
teams
Merchandising team: Takes care of our Buyers sampling and production. Withregular monitoring and update to our Buyers.
Quality Team: To ensure quality checks are done at every stage to ensure that correctsample is made and production according to our Buyers requirements.
Logistic Team: To take care of our Buyers pre and post shipment importrequirements
Motto of ourTEAM is to DELIGHT Our Customers by achieving the targets consistently
and competently
2.6.1 ROLES & RESPONSIBILITY
MANAGER (E&P)
To monitor negotiation team & administration team performance Shall procure stores material with least price, good quality at better delivery TAT To monitor & control all unit stores stock inventory minimizing non-moving items. Complying with suppliers, excise & commercial provisions. Have to take necessary actions for achieving quality objectives in our organization.
NEGOTIATION TEAM
To procure the required stores & spares keeping in mind of necessary quantity atcompetitive prices in consultation with manager(E&P)
To follow the on time delivery of the material.
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ADMINISTRATION TEAM
To collect indents from units & verify non-moving stock statement received from unitstores
Raise purchase order based on the quotation comparison/list price/order acceptance To raise auto purchase order to procure stores material from confirmed party without
indent, based on stores stock
To ensure compliance with all necessary actions for achieving quality objectives inour organization.
2.7 RAW MATERIAL
The raw materials are essential thing to produce the fabric cloth and the materials
used ultra-white, and various other color products like black, green. The company is being
purchasing these materials from reliance industries ltd.
2.8 MISSION
Will to win in the competitive world by exceeding expectations Achieving the hall mark of success, a platform to attract customers Treating every goal/ target as a challenge Motivation through team work
2.9 VISSION
INNOVATION: striving to be the best through being the first in all services andsolutions
QUALITY SERVICE: always setting a target to exceed expectations CUSTOMER SATISFACTION: Setting a chain reaction of satisfaction in each
customer and creating Reliability.
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3.0 DEPARTMENTS
The following are the various departments present in Elite Fabs.
- FINANCE AND ACCOUNTING-
HR DEPARTMENT- PURCHASE DEPARTMENT- PRODUCTION DEPARTMENT- ADMINISTRATION DEPARTMENT- MARKETING AND SALES DEPARTMENT
3.1 DEPARTMENT OBJECTIVE
To reduce the average lead time from 7 days to 4 days for packing materials by31.12.2010
To enhance the rate of reduction of the non-moving items from 15% to 30% by31.12.2010
To increase purchase of planned items from 60% to 75% by 31.12.2010 To purchase product at 5% lesser than the last three years average price as applicable
during the year 2009-2010
To reduce the delivery time (TAT) to cover 85 items by 31.12.2010 Monitor & measure the customer satisfaction on a quarterly basis & take steps to
fulfill their expectation.
3.2 RECOMMENDATIONS
Some customers are feeling price is very high. Many customers feel offer has to be improved. More awareness must be created among the customers through Advertisements.
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3.3 HR Department
3.3.1 Functions of the HR Department:
Production budget preparation. Fixing the work. Lead of individual workman. Calculation of ideal time and over time stoppage. Recruitment, selection and appointment. Wage and salary administration. Grievance handling. Employment benefits measures. Training and development.
3.4 FINANCE AND ACCOUNTS DAPARTMENT
Finance is the lifeblood of any business organization .It is concerned with allocation
of funds to various areas and Elite Fabs the best mix of financing in relation to the
profitability of the company. Financial System deals with all matters concerned with planning
in term of money.
3.4.1 MAIN OBJECTIVES
The main objectives of the finance and accounts as follows
y To establish the amounts of funds required for achievement of the objective anddetermine the Elite Fabs funds
y To ensure that the profits earned by the company are disposed of the best advantagesof the share holders and company
y To achieve maximum efficiency in the enterprise through proper planning,organization, control of financial resources.
y To achieve and secure safely investmenty To raise and maintain funds at the lowest cost possible
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3.6.1 PRODUCT RANGE:
30s To 100s, 100% cotton yarns in the following varieties. Karded /Combed. Ring Doubled/Two for one twisted Ply yarn(3/4/6) Auto Coned, Auto Leveled. Double hank plain reel/gross reel. Four hank plain reel/gross reel. Yarn conditioned Gassing yarn
3.6.2 TYPES OF PRODUCTION
Elite fab is very flexible in production as it follows the following production
techniques so as to cater to the needs of the customer.
Mass production:
Manufacturing of discrete parts or assemblies using a continuous process are calledmass production. This production system is justified by very large volume of
production.
Flow of materials and components is continuous and without any back tracking.
Make to stock production:
The manufacturer stocks the finished goods in inventory for immediate delivery. This system ensures immediate delivery of good quality, standard products. Elite Fabs follows this system in 30s and in 40s count. Because they are normally in
demand in
The domestic market.
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Make to order:
Elite Fabs Company also follows Make to order production. That is company makeor manufacture products after the receipt of the firm order from the customer.
They opt for receipt for the 70s and 80s count.Layout:
Elite Fabs follows the process layout in its working environment as everything in theProduction is concerned with huge machineries.
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3.6.3 Process of Purchasing Materials
Department Head
Purchasing Requirements
Getting sign from SM
Issuing to Store Keeper
Buying Quotation
Comparison
Choosing the best
Getting approval from SM
Purchasing Materials
Receipt arrival and receiving inspection
If not ok returning the faults
Settlements
Issuing materials to concern Departments
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Fabric Construction
In the weaving process, there is always a fixed relation between the ends, picks and
width of the fabrics with the yarn used in warp and weft. The numbers of warp yarn threads
required in one inch of fabric are called ends/inch and the numbers of weft (filling) yarn in an
inch of fabric are also called picks/inch. This relation indicates the construction of the woven
fabric. The construction having large number of ends and picks is called a heavy construction
and a construction having less number of ends and picks is called light constructed fabric.
The construction of a fabric is described as follows:
For example 20*20/108*58 = 63 1/1, tucked in salvage
Type of Weave
There are three main basic weaves in use for the majority of fabric.
Plain Weave
Twill Weave
Satin Weave
Plain Weave
It is the simplest type of construction. On the loom, the plain weave requires only two
harnesses. Each filling yarn goes alternately under and over the warp yarns across the width
of the fabric. If the yarns are closer together, the plain weave will have higher count.
Twill Weave
A distinct design in the form of diagonals is characteristic of the second basic weave
called the twill. The twill is frequently more tightly woven. Uneven four-shaft twill for
example that has one warp yarn riding over three filling yarns is referred to as three up and
one down, or 3/1. Staple yarn is usually left-hand twill. Wool type fabrics are usually right
hand twills.
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Satin Weave
In basic construction the satin weave is similar to the twill weave but generally uses
from five to as many as twelve harnesses producing a five to twelve-shaft construction. It
differs in appearance from the twill weave, because of diagonal of satin weave is not visible.
Weaving Machines
There are many kinds of weaving machines-looms in use today and the basic
difference in all of them is the technology applied for weft yarn insertion. Following are the
main weaving machine that is used in Elite Fabs
Machines No of Looms
Jacquard Looms (Rs 10,000,000 each) 14
(The machine name is Dornier, These machine have computerize system & make all type of
design and made by German)
Pat Machine 280cm (Rs 500,000 each) 56
(These machine have make a simple design & made by Japan)
Pat Machine 330cm (Rs 500,000 each) 24
(These machine have make a satin design & made by Japan)
Dobby Looms (Rs 6,000,000 each) 24
(The machine name is Zax Navy, these have make a dobby design & made by Japan)
Zax Machine 340cm (Rs 6,000,000 each) 12
(These also make a dobby design and made by Japan)
Zax Machine 280cm (Rs 6,000,000 each) 12
(These also make a dobby design & made by Japan)
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3.7 Total Machine-Looms
Weaving Process
The flow chart shows the basic flow of processes, which is required for weaving.
Warping Sizing
Drawing in Knotting
Weaving Inspection / Grading Folding Packing
Description of Weaving Process Flow
Warping
Warping is the process in which yarn from several hundred cones is wound on abeam. The yarn cones are placed on a rack called creel. From this creel, the yarn are wound
on a warp beam, which is similar to a huge spool. An uninterrupted length of hundreds of
warp yarn results all lying parallel to one another. Different types of looms require different
lengths and density of yarn for the weaving. Normally 650 kg yarn can be wounded on the
beam.
Sizing
The surface of gray yarn is hairy and during the weaving process, yarn is subject to
friction. In order to have better weave, efficiency and less breakage (wastage), the surface of
yarn is to be smoothened and the effects of friction are too minimized. This is done through
the sizing process.
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The purpose of sizing is to apply a protective film to the body of yarn in order to
enable it to withstand the various stress and strains, by which it is subjected to process of
weaving and enhancing its strength and elasticity.
Yarn is coated with maize starch, PVA (poly vinyl acetate) or water-soluble polymers to
prevent it from chafing or breaking during the weaving process.
Calculation of creel beams required for warping 20*20/108*58 = 98 fabric construction
Total ends = (No of ends * Width) + Selvedge ends = (108*98) + 10 selvedge ends =
10,594 ends Creel capacity = 672 (Maximum creel capacity of warping machine)
No of beams required = Total ends / creel capacity = 10,594 / 672 = 15.75 or 16
Beams, so one set for sizing consist of 16 beams i.e.16 beams are to be sized for making one-
warp beams for feeding on the loom.
Drawing in
Purpose of the drawing in process is to prepare yarn for weaving on looms. Ends of
the yarn are passed through the eyes of the healed. The process of drawing warp threads
through healed and reeds is known as drawing.
Knotting
When the yarn on warp beam mounted on the loom comes towards an end, and more
similar variety is to be produced, the yarn from the old beam is knotted with a new beam,
either manually or with the knotting machine mounted on looms, in this case drawing-in does
not have to be performed and time involved in drawing in process is eliminated.
Weaving
The sized and drawn in beam is mounted on the loom at one end and the warp yarns
are conveyed to a cylinder called the cloth roll at the other end, between the eyes of healed
and reed dents. In order to weave fabric, two separate yarns are used i.e. warp yarn and weft
yarn. Warp yarn are generally stronger yarns with more twist per inch and weft yarn are
comparatively softer yarn with lesser twist per inch. In shuttle less weaving, however, this
practice has been eliminated and similar yarns are used for warp and weft to ensure quality
and uniformity of the finished fabric.
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Inspection and Grading
The woven fabric on the beams from the looms is taken to the inspection department
for inspection and grading. The fabric inspected by trained staff on the machines. The fabric
is graded as A B and C, depending on the fabric faults.
There are two fabric grading systems via, Japanese and American. Brief description of
two systems is given below:
Japanese System
In this system, if the total faults per 100 running yards (length and width including),
are up to 80 Points, the fabric is called A grade.
American System
In this system, if the total faults per 100 running yards are up to 25 points, then the
fabric is called A grade,
The points are calculated as follows:
Japanese American
A) One major fault 10 points 4 points
B) Half width fault 5 points 3 points
C) Below half width more than 6 inches 3 points 2 points
D) Below 6 inches width 1 points 1 point
The rejected fabric having minimum piece length of 40 yards or above is called B
grade and if the piece length of the rejected fabric is from 9 to 39 yards, it is called C grade.
If the piece length of fabric is below 9 yards it is called rags. Major cloth faults may be due
to warp or weft yarn poor quality, improper maintenance of loom, poor quality of auxiliary
devices and carelessness on part of weaver.
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3.8 Major Fabric Fault
Warp Marks
Longitude strips along warp may cause missing of one or several warp ends.
Miss picks or set marks
Strips over full and partial width of cloth, improper working of weft fillers, improper
loom stoppage, negligence of weaver.
Difference in warp yarn and weft yarn density
Thick and thin places, improper working of let off motion or fabric takes up motion,
faulty operation of fork, weft filler, improper loom stoppage, etc.
Irregular pick
Variations in weft count, irregular operation of take up and let off motion.
Bad selvedge
Slackening of selvedge ends, improper winding of fabric edges on cloths roll,
improper winding of warp on weavers beam.
Over shoots and fluffing
It is formed by weft yarn, which fails to inter lace with warp and accumulation of fluff
on weft yarn.
Oil stains and dirt on cloth
Careless oiling of looms, dirty hands of weavers, and condition in the shed.
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Major Yarn Fault
Thick and thin yarn
Thick and thin yarn will effect, the warping and sizing. In warping the yarn is
mounted on the warp beams at a certain tension and due to the thin places, the yarn will break
frequently. In sizing, the thin and thick yarn will absorb the sizing material in different
percentages and the sized beams will affect efficiency of looms.
Shade variation and count variation
Yarn prepared from cotton having low staple length will create excessive breakage
during warping and sizing.
Low staple yarn
Yarn prepared from cotton having low staple length will create excessive breakage
during warping and sizing.
Fluffy yarn
Yarn having fluff on it will create harshness on the woven fabric and it will be
difficult to dye
Folding
The inspection department, send the fabric length to folding department in which all
the fabric is folded as per the type of fabric lengths and grades.
Packing
After folding, the fabric is shifted to packing department and the packing department
will pack cloth as per its requirement. For exports the fabric is packed in exports sea worthy
rolls and bales. The bale packing is from 500 yards to 1000 yards or as per buyersrequirement. Some buyers require fabric in roll packing because it is easy for them to put on
the dyeing/finishing machines.
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3.9 PROCESSING DEPARTMENT
The company has continuously invested on hi-technological automated system as well
as modern instruments and equipment. The equipment installed at processing plant has been
sourced from world-renowned manufacturers, thereby enabling Elite Fabs to produce
products conforming to international quality standards. It is strongly anticipated that our
investments will be endless owing to the fact that we are living in an era of dynamic and
unceasing technological innovation currently the processing plant is designed for a
production of 3 million meters of printed and 1.5 million meters of dyed fabrics.
The production of dyed cloth is going to increase to 2 million meters as of January
2005. Printing includes pigment, reactive and vat printing with direct, discharge and resist
methods, and continuous dying on pad-dry-thermo sol and pad-dry-steam. It specializes in
several finishes, e.g. oil and water repellant, anti microbial (anti bacterial, anti static, anti
fungal, anti moth etc.), anti static, up protective, flame retardant, down proof, crease
resistance and wrinkle free, chintz, and special silicone (hydrophobic and hydrophilic).
Woven Gray Fabric Processing
Gray fabrics must be cleaned before they can be put into the finishing process. It
contains sizing material and may also contain oils, other additives and dirt. Complete removal
is necessary in order to finish, dye, and/or print the fabric effectively. The method of cleaning
depends upon the fiber in the fabric, the kind of impurities present, and the construction of
the fabric. Finishing and processing is categorized in several ways. Those concerned with
textile processing may classify them as wet and dry finishes, respectively.
Gray fabric processing and finishing can be categorized into three major classes.
White Bleach
Dyed
Printed
The designers, merchandisers, sales personal, and others are concerned with end product.
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White Bleach
If the cloth is to be finished white or is to be given surface ornamentation, all natural
color must be removed by bleaching. This is also necessary if discoloration stains have
occurred during the previous manufacturing process. Bleaching can be done in the yarn stage
as well as in the constructed fabric.
Dyeing
Dyeing and printing differ in the method by which color is applied to fabric. In the
dyeing process, fiber, yarn, or fabric is impregnated with a dyestuff. To select the proper dye
for a fabric, it is necessary to know which dyes have an affinity for the vegetable, animal, or
manmade fibers.
Printing
In printing, a pattern or a design is generally imprinted on the fabric in one or more
colors by using dyes in paste from or some related means. One form of applying colors
decoration to a fabric after it has otherwise been finished is called printing. There are three
basic approaches to printing a color on a fabric: direct, discharge, and resist.
Woven Fabric Process Flow Chart
The flow chart shows the basic flow of processes, which is required for processing.
Singing and De-sizing
Batching Bleaching Scouring Mercerizing Tendering Dyeing Printing
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Tendering/Finishing
Glazing
Embossing Wash and Wear Finish Calendaring Sunforizing Inspection and Folding
Packing
Description of Woven Fabric Process Flow Singeing and De-sizing In order to
remove the extra fibers from yarn used in cotton or cotton blended fabric weaving, and to
have a smooth finish; singeing is one of the first essential preparatory processes. Singeing is
necessary in order to eliminate the pilling effect on fabric, which may occur due to extra fiber
on the yarn surface. Spun rayon fabrics are also frequently singed. But wool and silk fiber
and would melt resulting in balls on the surface of the fabric. Singeing is accomplished by
passing the gray fabric rapidly over gas flames, usually two burners to a side.
After the cotton cloth leaves the burners, for de-sizing (removing the sizing material),
it is pulled through a solution of an enzyme to digest the starch with which the fabric iscomposed.
Batching
After applying the de-sizing agents, the fabric is rolled on and is constantly rotated,
with polythene cover outside, in order to keep it wet from all sides. This is done to have
chemical reaction of the enzymes with sizing material (for breaking the sizing material). PC
fabric is kept in batching for 4 to 8 hours and the cotton fabric is kept for 8 to 16 hours.
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Bleaching
Bleaching makes the cloth ready for printing. The fabric undergoes three washes. First
two washes are with the boiling water and the third is with a 60-degree hot water. Bleaching
can be done in the yarn stage as well as in the constructed fabric. The kind of chemicals to be
used depends upon the kind of textile fiber of which the fabric is composed.
Scouring
Scouring is a process, in which the fabrics are given special washes to increase their
dye up take. The chemical react with the cellulose of the fabric. In this process the fabric is
passed through chemical of scouring agent and the wetting agent. These chemicals allow the
fiber to swallow and the dye up take will increase. Scouring is done primarily for the fabric
dyeing.
Mercerizing
Mercerizing is an important preparatory process for cotton fabrics. Mercerizing
causes the flat, twisted, ribbon like cotton fiber to swell into a round shape and to contract in
length. The fiber becomes much more lustrous than the original fiber, and its strength is
increased by as much as 20 percent. Its affinity for direct, vat and reactive dyes is much
greater. The processes consist of passing the fabric through a cold 15 to 20 percent solution
of caustic soda. It is then stretched out on a tender frame where hot water sprays remove mostof the caustic. A special washer at the end of the tender removes the balance of the alkali. The
process is continuous.
Tendering
This process is applied at various stages of finishing. Usually a fabric is wet when it is
run into a tender; drying and evening of the fabric width are the primary purposes of
tendering. The tender frame consist of two endless chains carried in rugged rails with clips or
pins, which grip the selvage of the fabric and carry into the heated housing where a blast of
hot air removes any moisture.The tendering process is to keep the warp and weft yarns
straightened and give crease resistance to the fabric. It is an end process for white bleached
fabric. Printed and dyed fabric has to pass through the stander first the bleaching/scouring
and second after printing and dyeing.
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Dyeing
In the dyeing process, fiber, yarn, or fabric is impregnated with a dyestuff. To select
the proper dye for a fiber, it is necessary to know which dyes have an affinity for the
vegetable, animal, or manmade fibers. There are several types of dyeing machines devised for
different kinds of fabric with different kinds of raw material. When a dye colors fabric
directly with one operation of impregnation, without the aid of an affixing agent, the dye is
called direct dye.
Following are the main dyeing methods:
Stock dyeing: The process of dyeing is done in the fiber stage
Yarn dyeing: The process is done after the fiber has been spun into yarn.
Piece dyeing: The dyeing is done on the fabric.
Garment dyeing: It is done after certain kinds of apparel are knitted.
3.10 Export Department
Export department plays a vital role in any organization. Elite fabs export department
is headed by the export manager. The export manager supervises all the marketing and export
activities. Export manager is also responsible for the exploration of local and foreign markets.
He is also making efforts for the development and the progress of the company.
3.10.1 Objectives
To increase the export of the Grey Fabric and Yarn.
To maximize the company profit by increasing exports.
Exploration of the new markets.
Market research making the better information system.
Adopting the new technological a development changes in the field of textile.
To build the image a credibility of the organization.
To earn foreign exchange for the progress of the economy of the country.
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3.10.2Functions
Following are the main functions of the export department.
Export department is responsible for the production planning and the production Follow-up
with the mill.
Customer correspondence as well.
Export department also follow-up the local sale and purchase of the yarn and the
Gray Fabric.
The important function of the export department is to make shipment schedule and the
planning.
Visiting to the existing and new customer.
Providing timely information about the production of the products to the customers which is
also providing a service to its customers and promoting the company image.
Improving the quality of the products with collaboration with the buyer and the production
department.
Bank documents preparation and the follow-up.
Preparing the custom documents.
Dealing with the agents and providing timely information to the parties.
B/L follow-up with the shipping lines.
Export updating system is also the responsibility of department.
Preparing the quality analysis report and sending them to higher authorities.
Maintaining the complete sale and purchase records.
Export department is helping in improving the quality and betterment of the products and
the company.
Providing timely information to the clients is the main service provided by the Elite fabsTextile (Pvt) Ltd export department.
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3.10.3 Export Documentation
Export procedure is a very lengthy process. It involves a number of documents
required by the importer from the exporter. Elite fabs Textile (Pvt) Ltd export department
carefully handle all the steps involve in it. Because a little bit of mistake can cause a great
loss to the exporter and the importer.
Indent
Sales Contract
Letter of Credit
Custom Documents
Packing List
Bill of Lading
Bill of Exchange
Certificate of Origin
Inspection Certificate
Shipping Bill
3.10.4 Custom Documents
The custom documents are very important because it provide the evidence that goods
have been transported and it enables the importer to receive the goods from the custom
authorities. As the order placed by the importer is ready on the due date, the export
department issues the dispatch order to the mill. That the following quality should be
dispatched on the containers specified on this L/C. The goods are loaded on the specified
containers and they are sent to the Karachi port on the specified line. ELITE FABS mostly
does its shipment through the shipping companies.
The shipping lines charge their freight and other charges are paid the agents as well as
for clearance of the goods from the port. The agents handover the documents which involve
packing list and invoices to the shipping lines. As the trailer number, the container number E
form number, quality and the quantity is completely mentioned on this invoices.
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Mode Document Carrier
By sea Bill of lading shipping lines
By Rail Receipt Railway service
By Road way bill Transporter
By Air way bill Air lines
Packing List
Packing list is a document which involves all the complete list of the goods packed in
the particular shipment. It is very important document. It provides a convenience to the
shipping and the clearance authorities.
Features of packing list
It usually shows the marks a number mentioned on the packages.
It shows the weight also.
Each package is marked by a number.
It shows the contents of each package, what is nature, quality and quantity of the
package.
It provides a linkage with the other documents to reference to the invoice number,
date, letter of credit number, and date and vessel name.
Bill of Lading
Bill of lading is one of the most important documents in the whole export documents.
Because without this the importer cannot receive their goods from the destination port.
ELITE FABS first of all drafts the bill of lading and that is sent to the shipping line.
Bill of lading also contains the specifications related to the importer and the exporter. The
name of the exporter, place, the importer, the bank, the quantity is mentioned, the quality is
mentioned, the quality with all specifications required by that, the total value of the goods
which are exported. The date of the bill of lading is mentioned.
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The shipping line and vessel name is given on B/L. Bill of lading is a comprehensive
document that is issued by the shipping line. The date of shipment is also mentioned on that.
Without this the importer cant clear the goods from the destination. ELITE FABS export
department also very quick in follow up of the B/L because they have to transfer the
information to the parties.
Bill of exchange
It is unconditional order in writing, addressed by a person to another, signed by
person giving it, requiring the person to when it is addressed to pay on demand or at a fixed
determinable future date. When the L/C is opened the B/E must be strictly drawn according
to the terms and conditions of the creditor may be drowning on the request of the applicant or
on the bank request through which the credit is opened. B/E is also a important document of
export.
Certificate of Origin
Certificate of origin shows that the good which are being exported are originate from
a country form which importer is allowed. These are required by the authorities in the
importing countries. In order to satisfy and support a claim for the import duty. The
certificate of origin may also be made by the consultants of the importing country in the form
of consoler invoice or legalize the exporters commercial invoice. When explorer called for
L/C, of is with the other documents by reference to the invoice number, L/C number and by
quoting shipping marks and number in order to identify the goods.
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4.0 ADMINISTRATION DEPARTMENT
This is very important department of the organization as the name shows; this
department has to administrate all the operations of the organization. This is handed over to
the A.M (Admin. Manager) of the company who is retired Army officer.
Sections of this department are divided into offices as under:
Labor Office
Security Guard Office
Gate Office
Time Office
4.1 Labor Office
As required by the labor department of the Govt. of Pakistan, this office has been
setup to deal with all the matters that are related with labor. The department is under the labor
officer. He is responsible to resolve all the disputes, conflicts, misunderstanding and any
other kind of matter which may arise from time to time with the labor and the immediate
supervisor or with any other person in the organization. It is the duty of the labor officer to
inform the legal requirements concerning the labor and company affairs as well as any
changes in the labor laws.
It is also the duty of the labor officer to satisfy itself regarding payment of bonus,
gratuity, and the other benefits to labor and to keep their morale and motivational level high.
It is also a requirement to be a successful labor office that he should keep his knowledge up
to date regarding the rules and regulations of the labor department.
4.2 Security Guard Office
The main objective of the security office is to safe handling of the goods from / to themill premises. For the achievement of such objective a team of security guards has been
employed by the company.
All the keys relating the mill office, labor colony, (quarters) are lying into the responsibility
of the security officer.
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No outside visitor can enter in the mills premises without the permission of the Admin
Manager.
Whenever any visitor wants to enter into the mill, security guard firstly contact with the
authority in the mill to grant the permission to enter into the mills premises.
Security guards can check each and every person before coming in or going out of the
company gate for the security purposes.
They see and check the outward going pass of the certain things when these going to out of
the mills premises.
They are the guardians of the everything of the company.
4.3 Gate Office
This office has been made to keep the record of each and every thing coming into and
going out of the mills gate.
For this purpose gate office clerk maintains two types of register called;
1. Outward going pass register
2. Inward going pass register
When everything including raw material, stores supplies, or any other thing comes into the
mills premises a document named as I.G.P is made in which information like date of supplier,
description, quantity of the material and any other remarks are written. In the same way
O.G.P is prepared for outgoing things etc and they made a summery on daily basis and fax to
Head Office.
4.4 Time Office
This office keeps and maintains the time record of all the workers on incoming time cardsand pay register for the final preparation of the workers salaries.
It keeps the attendance records, which is then used to calculate the salary to be paid to the
workers on monthly basis.
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It keeps the records of the over time single as well as double, leaves, number of days
worked of all the workers and then calculate their over time on the basis of the gross salary of
each worker.
It keeps the records of Social Security and Education Cess etc of each employee / worker
payable to government treasury.
It keeps the records of Gratuity, Bonus, Pensions and other benefits including CPL (Cash
Paid Leave) to each employee / worker of the organization.
Core Competencies
The core competencies of the firm includes
Technology
Work Force
Facility
Market Experience
According to management one of the factor, on the basis of which they are competing in the
market is the technology of their product.
The next important thing is the work force according to management; our employees
have been the backbone of the company. They deserve to be given the right condition and
right environment for them to grow and prosper. Throughout the history of the company,
management has prided themselves in its excellent relationship with its employees. This bond
has been recognized as one of the most important ingredient of our recipe for success.
Facility of the firm is also one of the core competencies of the firm. Customer and supplier.
Similarly the market experience is another core competency.
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5.0 MARKETING DEPARTMENT
The companys products are in good demand for the past several years. Hence no
difficulty is anticipated in marketing. The company entered into export market in a humble
way recently. This will be expanded to the best possible extend in future .The entire sales of
the factory are being directly controlled by joint managing director of the company with the
two assistants of junior officers.
They manufacture the yarn based upon the demand and the requirement of order.
They are fully capable to sell what they produced. They gained 5% of Salem yarn market,
10% of Nagari market and 2 % of Coimbatore market. Their share in Indian yarn market is
only 0.61%.
5.1 YARN SALES:
Yarn is manufactured by spinning unit and taking into current total market
requirements, exports order and yarn required for the weaving unit. Accordingly yarn is
manufactured in opened, cut the sophisticated order machines and through ring frames as per
monthly production programmers Chalked out.
5.2 DIRECT SALES:
The sales concluded directly to the buyer from the seller without any mediator. The
company enters into a contract directly with the buyer. The goods must be sent to the buyer
within the stipulated period as per the contract. The contracts have been entered into the
parties as per the terms and delivery of goods and sending of invoices either directly or
through bank will made. Another copy is sent to accounts department. At the time of receipts
of invoices, accounts department debits the parties account and when the cheque is cleared
credit the parties account. If due means periodical follow ups are made.
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5.3 Marketing Mix
Marketing mix is the set of marketing tool that the firm uses to get its marketing
objective in the target market.
4Ps
1. Product
2. Price
3. Place
4. Promotion
Product
The company is committed to produce and achieve excellence in high quality
products. The products range is extensive and includes all sort of curtains, kids bedding,
fashion bedding, traditional bedding, basic bedding and kitchen articles. As a fully integrated
textile manufactures, the companys products range is extensive. It includes various types of
fabrications and blends, such as 100% cotton, cotton lycra, cotton polyester, cotton silk, etc.
The focus is to make differentiated products by using different types of fabrics, such
as solids, dobbies jacquards, etc, and creative styling in the make-up to give high value for
money.
Price
Pricing is an important element in the marketing process for any company. The price
policy of company must be in such a way that it should produce a reasonable profit, for the
company and should satisfy the customer.
Following two factors are very important.
Fixed Cost
Variable Cost
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Fixed Cost
Fixed cost is the cost which remains always same in total whether produce large
quantity or small quantity. Fixed cost per unit rises as the quantity produced decreases and
vice versa. Some companies always try to use their full capacity of production because with
increase in production the fixed cost decrease. Following are some important factors of fixed
cost. Some examples are:
Salaries & wages
Rent
Local Taxes
Fixed cost in value, the cost related to the machinery.
Building cost
Electricity change
Insurance expenses
Plant cost
Variable Cost
Variable cost changes in total with the change in quantity produced. It increases as the
level of activity increases. Per unit variable cost remains same whether to produce large or
small quantity.
Some examples are:
Material Cost
Factory Overhead
Part time Workers
Transportation Charges
Miscellaneous
Fixed cost + Variable cost + Desired profit = Total cost
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5.4 Pricing Objectives
The obvious pricing objectives of Elite Fabs Textile are,
Maximization of profit
To achieve the target return and targeted sales
Maintain the market share
5.5 Pricing Strategies
ELITE FABS adopts following strategies in case of pricing fixing:
Direct Selling
Agent Selling
5.5.1 Direct Selling
If company sells directly then price components will be as follows:
Fixed cost + Variable cost + Desired profit
5.5.2 Agent Selling
If company sells to the customer through agent then fix price in this way:
Fixed cost + Variable cost + desired profit + Middlemans commission
The profit margin depends upon the quality and condition of the market. If the market
will new obviously price level will be low to attract the customer and complete with the
existing competitor.
5.5.3 Pricing Procedure in Local Market
Elite Fabs sells locally only extra quantity left from the foreign order. They call tender
when they want to sell the production in the local market. They sell to those persons whose
tender price will be high. Sometimes, ELITE FABS sells its product itself, when some extra
quantity is left from foreign order, they sell at suitable cost.
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5.5.4 Pricing Procedure for Export
Pricing procedure for export is different from the local procedure they charging the
price in foreign factors before charging the price in foreign market. When any customer
wants to purchase the products, after negotiation they fix the price. Some important factors
are inland freight, sea freight, clearing charges, etc.
5.5.5 Place / Distribution
ELITE FABS exports more than 90 % or its product. So, they are using two types of
distribution channels in export.
Direct Channel
Indirect Channel
5.5.5.1 Direct channel
ELITE FABS is also dealing directly with the customers. As in the local market and
the foreign, the buyers direct contact with the ELITE FABS. So the export departments fulfill
their orders by the transformers. The transporter helps in delivering the products. The
transporters are helping a lot in progressing the textile industry. The comely delivery to the
buyer is the greatest service to the customer, timely delivery is important for the success and
development of the organization.
5.5.5.2 Indirect channel
ELITE FABS to agent & to customer. In the export of textile products, the agents are
the back bone of textile industry. They receive order on the behalf of buyer, give to the seller.
They receive their commission from the buyer and the seller.
The agents also purchase the products; sell them directly to other buyers. So in this trading
they earn enough profit. There have been a large number of agents which are working for their organization in
foreign countries as well as in this country.
Mostly the export business is through these agents. The agents have been successful due to
credibility and honesty of their work.
ELITE FABS mostly receives orders through agents.
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ELITE FABS pays commission to them.
Mainly the responsibilities lie on the agents in case of delayed shipments, payment
problems and the quality problems.
As most of the product of Elite Fabs are exported. So, they use different modes of
transportation to transfer the product from Elite Fabs to customers country.
Mostly Elite Fabs export its products through ship. They are other modes of transportation
also being used
Trucking
Shipping
Air Lines
5.5.6 Promotion
Elite Fabs promotes its products, but to a limited extent.
Elite Fabs provides the company broachers to the buyers.
Elite Fabs provides the samples of the grey fabric. The yarn to the customers.
Elite Fabs has a direct contact with the local and the foreign agents, so they also
promote the company products.
Visits to the customers.
Elite Fabs marketing manager also visits its customers.
Their high quality of the products on the fine count the grey cloth is also promoting
the company and establishing image and goodwill.
Elite Fabs provides the timely information to the customers which help in
promoting. Observation and Suggestions
As the textile industry is in crisis but Elite Fabs Textile Mill limited is performing
very well in such difficult economic conditions. The avenues are always open for further
improvements. I hope that the suggestions given by me that will not only benefit to the
management for getting business but the workers will also efficient in performing their
duties:
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There is centralization of authorities. The Chief Executive and the working Directors take
all the decisions. The authority should be decentralized, because delegation of authority
creates responsibility. If the management will delegate some authority to employees then
employees will feel themselves responsibility and they would work with zeal.
I would like to recommend that management should develop some policies for the
promotion of efficient workers. As there is no any policy for the promotion of the workers, so
it creates unrest among the workers.
There is need for refresher courses for the managerial level employees. If the owners would
make arrangements to provide training to the employees then they would work efficiently. By
doing so the productivity of employees would be improve.
The culture of the organization should be developed as according to the well-established
organization.
The control of the top management should be very strict over the employees so those
employees will take responsibility for their assign job.
Proper training should give to new employees as well as the existing employees for the
improving of their efficiency and productivity.
There is no any procedure for evaluation the performance of employees and hence there are
no extra benefits to the efficient employees. The worker must do work more efficiently when
there would some kind of prize would be given to them, the prize must be as the employees
of the day, month, or years.
There is flat rate of increment for all the employees. This flat rate is also minimal. This is
breading discontent among the employees. The increment should also be given on the basis
of performance and efficiency.
There is lack of staff members in the office, so there is need for the appointments of new
employees to diversify the load of work from the existing employees.
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6.0 SWOT analysis
6.1 STRENGTHS
y Well organized and experienced staff.y Innovative and customer oriented products.y Direct approach to the customer.y Customer satisfaction.y Strong distribution network.y Efficient and fast delivery system.y Good subscription gifts.y
Have separate group for Hindi magazines
6.2 WEAKNESS
y Price of some magazines is high.y They are reluctant in promoting some of their own products.
6.3 OPPORTUNITIES
y It has many products capturing all sectors information so it has an opportunity tobecome a market leader.
y Career 360 is a very good career magazine.
6.4 THREATS
y Existing competitors in the market.y India today has already captured the big market share.
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CONCLUSION
It was really a great opportunity for me to get trained in an organization on the various
aspects of business. This training helped me know that, every company, especially the
garment company has to improve the advertisement and marketing activities as well as the
company has to concentrate on price & offer programmer. The company has to use new
technologies for developing variety of fabric products in industry. It may very useful for
sustain the position in the textile industry.
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