project repot - rivaa exports

8/9/2019 Project Repot - Rivaa Exports

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Contents

Objective: ................................ ................................ ................................ ............................. 3Introduction: ................................ ................................ ................................ ......................... 3Analysis Of Plant Location Considering Various Factors ................................ ...................... 5Utilities Of Production And Their Availability: ................................ ................................ ..... 6Organization Structure Of Production Department ................................ ................................ 8How Production PlanIs Prepared From Sales Plan................................ ................................ 9How Production PlanIs Converted In Material Requirement Plan And UltimatelyIn PurchasePlan: ................................ ................................ ................................ ................................ ..... 9Material Receipt Procedure: ................................ ................................ ................................ 11MaterialIssue Procedure: ................................ ................................ ................................ .... 12Purchase Procedure: ................................ ................................ ................................ ............ 12Inventory Control System: ................................ ................................ ................................ .. 13Different Records Kept In Store: ................................ ................................ ......................... 15Types And Classes Of Material-Handling Equipments: ................................ ....................... 16Classification OfInventories According To Abc Analysis And Ved Analysis: .................... 18Maintenance Planning System: ................................ ................................ ........................... 20Records Related To Production Operations At Different Machines: ................................ .... 21Production Process................................ ................................ ................................ .............. 24List Of Plant & Machineries: ................................ ................................ .............................. 33


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Objective:

To observe and understand the production process ofa dyeingand printing mill.

Introduction:

Rivaa Exports Ltd. isalimited company incorporated in the year 2001. The company isset

up with the main object of manufacturing, processingand marketing of dyed, printed andembroidered fabrics. RIVAA is one of the renowned names in textiles, which has domestic

and overseas market clientele. Inshort span the companygot the status of Governmentrecognized STAR EXPORT HOUSE. The company markets its product under the brand

name Rivaaand got registered with Registrar of Trade Mark, Government ofIndia underclass 24 and 25.

The Registered office of the Company isat Rivaa House, Udhna Darwaja, Ring Road, Surat,

Gujarat,India. Facilities for Embroideryare at Survey No. 4& 8, Village Sonari,

Sachin, Surat, Gujarat and at Plot No.A-5/1, HojiwalaIndustrial Estate, Sachin PalsanaRoad,Vanz, Surat, Gujarat. Dyeingand Printing division isat Plot No. 803/1, GIDC, Sachin.

Rivaa Exports is equipped with world class technologiesand modern manufacturingmachineries to provide best quality products to our esteemed clients.

The company has been founded by the visionary entrepreneur Shri. Harish Virmani. He is

one of the renowned personalities in the textile businesssince 25 years. He hasstarted hisbusiness carrier inyear 1984-85, his innate ability to foresee the future, closelyanalyzingand

understanding the nuances of day to day operations, quickand rapid implementation, helped

him to build a company with strong foundationsand corporate ethos.

The Directors possess high business caliber, talent, intelligence and high businessacumen

along with rich and vast practical experience. Enriched and well-established reputation of thepromoter withinand outside the country has enabled the company to achieve the desired

results.

The Management of the company is well experienced in the textile industryand is quality

conscious. To lookafter the entire operations, the company has built technically qualified and

experienced team ofassociates. The management rests in the capable hands ofan expert

team,grounded in the realities of the business. With decades of experience, theyare highly

knowledgeable about each and everyaspect of fabric, dyeing, printingand embroideries.

The Company is into manufacturingand exporting of Textile Fabrics especially value addedladies dress materialsand Sarees.. The company has fully computerized Embroidery unit

comprising of Swiss Made Schifily Embroidery Machines, Chinese/Japanees made Multihead, Laser Cut, Cording, Tapping Embroidery machines. The company hasIn-house

Research & Development Department for developingnew designsand patternsand toimprove the quality of the products, to innovate and to touch new paradigms of designsand

concepts.

The company has its presence in PAN India, USA, Canada, U.K., Middle East, Malaysia,

Singapore,Indonesia South Africa, etc. Some of our precious Local buyersare SDM Fabrics


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Pvt. Ltd (TACFAB), Chabra Trading Company Ltd. (CTC)Delhi, Nalli Silk Stores, ShriKrishna Collection, Pothys, The Chennai Silk- Chennai, Sarthas- Trichi, Neerus-

Hyderabad.

The entire organization of the company thrives hard asa team to achieve new goalsand to

meet the challenges of the future by continues improvement and implementation ofnew

methods under the able leadership of Managing Director Shri. Harish Virmani


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Analysis OfPlant Location Considering Various Factors

Forany production unit location of plant also play important role in profitability,so location

should be co operating with various factors. As each coin has two sides there are both

positive and negative points of plant location but positive point is on heavierside. Theyareexplained below inshort.

POSITIVE FACTORS:

y The location of unit is in the outskirts of Surat city which 100% suits the governmentnorm. According to government rule production unit should be away from the

residentialarea.

y Being in the outskirtslocation isnot much far from the main textile market where allthe customers exist.

y Also the entire suppliers production unit of colours, chemicalsand othersare in thesurroundingarea only.

y Labour are easilyavailable here because majority of la bour class workers dwells innearbyareas only.

y At thislocation the company isnot required to install the waste water treatment plant,which isa very major concern fora textile mill in terms of cost and its management.

Because in Sachin a common waste treatment plant is installed by the government

which isnot present in otherlocations of the city.

NEGATIVE FACTORS:

y Mainnegative point here is the availability of water. Here boring water is too hard tobe used for dyeing purpose. So companies here use watersupplied by Sachin GIDC

which increase anominal cost to overall cost. Boring water can be used but onlyafter

some treatment. The totalaverage required quantity per day is 10-11 lakh liters. Many

a times this requirement isnot met due irregularsupply of water from the GIDC. So

to cover the gap water tankers from private suppliers are ordered which further

increases the cost.


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y Other problem is staggering problem. There is a power cut here every week onSaturday. So company has to eitherstop production orgenerate power by their own.

Utilities OfProduction And Their Availability:

Power Generation

The company has connected a power load of 650 KVA with GEB which shows maximum

limit of utilization. The company hasalso installed two D.G. set each of 200KVA, 600 KVA

respectively,so as to ensure continuity of production during power failures. The company

also has one steam turbine attached with boiler which generates 300 KVA of power. Daily

average usage of electricity isaround 9000 to 9500 units per dayand the average monthly

power bill comes to around 12-13 lakh per .

Steam Generation

Boiler is used to generate steam. Boiler issaid as the heart of the dyeingand printing unit and

steam as running blood. Almost on each machine except stentersteam is used ina dyeingand

printing firm. The boiler used here isnamed as F.B.C coal fired combine bio drum HP boiler.

Its capacity is 5 TPH (Ton per Hour). Water used here should be as hot as 80 degree

centigrade.

Raw Material

The ma jor raw materials required are colours and chemicals such as polyester threads,

sodium chloride,sodaash,naviline,solventsacidic acid, blue coat, cotton citric acid, caustic

soda, dispensingagent,levelingagent, etc.

These are manufactured by manysmallscale unitsand a few big industrial houseslocated at

surat and surrounding towns which are manufacturing these colours and chemicals. All the

essential raw materialsare available inadequate quantity, in Surat and Atul. Those units that


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are located outside are having their stores at Surat. Majority of the colour chemicals is

supplied bya companynamed Colourtex, which isa market leader in this industry.

Coal & Gas

Imported Coal is main fuel, which the company already has sufficient connection with the

localsupplier of the same. The daily consumption of coal is 12 to 14 tonapproximately. Gas

is supplied by Gujarat Gas Company for immediate firing purpose in the boiler. Gas

consumed is 4000 cubic/meter.

Transportation

The company hasalready bought for itself two big tempos. The private tempos really help the

company forsmooth flow ofgoods to its customer, without any disturbances (e.g. strike).

Water

The water is been made available to the unit by Sachin GIDC. Total consumption of water is

8 lakh liters per day for dyeingand around 3 lakh liters for printing purpose.

Manual Labour

Forsufficient and successful operation of the project, the units propose to employsufficient

staff for working on two shifts. There are around 800 people working in the company.


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Organization Structure OfProduction Department

OTHERS TECHNICIANS

ENGINEERS MAINTANANCE

DYEING

MASTER

PRINTING

MASTER

ASSISTANT

MASTER

DYEING

INCHARGE

SUPERVISOR

LABOUR

CONTRACTOR

WORKERS

ASSISTANT

MASTER

PRINT

INCH-

ARGE

SUPER-

VISOR

LABOUR

CONTRA

CTOR

WORKERS

PROG

RAM

MERS

PRODUCTION

DESIGNERS


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How Production Plan Is Prepared From Sales Plan

Production Plan isa very important factor related with productionactivity. The process of

preparing production plan from sales plan in dyeing industry is knownas programming.

The customer first ofallgivesgrey cloth in the mill but doesnot give order for designsand

colour combinationat the same time. But then, production manager i.e. master doesnot wait

for his order. He starts the dyeing process which is obvious procedure which isnot dependent

on designs or colour. After this process is completed the grey cloth isnow said as bleached

fabric. This bleached fabric isnow kept in the white department till the designsare finalized.

When customer finalizes the design,and thenstarts the printing process on first come first

serve basis. Some times on demand of regular customers, priority for early production is

given. Production plan is of course planned considering factorslike process time, due date

and available time.

How Production Plan Is Converted In Material Requirement Plan And

Ultimately In Purchase Plan:

Material requirement planning is generally a program which shows the quantity of raw

material that is required for the fulfillment ofa particular order. It satisfies the requirement of

production department ofaccuratelyallocating the raw materials to a particular order.

Once production plan is prepared, production is to be stated but for that raw materials are

required. So now the furtherstep is to calculate the requirement of inputs without which the

production cannot begin.

Whenever the orders are received from customer they are jotted down in the form of an

accurate production plan and sent to the concerned supervisor. The production manager,

machine supervisorand the store manager work in coordination and lookout for the inputs


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required for productionand also analyses the production plan to find out the capacity of the

machine.

They calculate the material requirement by considering the quantity required for one unit of

output and then device the requirement for entire output. The current stock level, pending

purchase order of raw material isalso administered.

Thus the planners first collect all orders, analyze them & finally give the material

requirement quantity. This material requirement is sent to purchase manager through a

purchase indent. He then verifies the order with the store and then places the orders.

Example

BILL OF MATERIAL:

STEP 1: End product

Saree 1 unit

STEP 2: Requirements to make end products

Usable Gray 1meter

Dyeing process

Printing process

STEP 3: Requirements for drumming of gray

Caustic 7 grams

Soda Asn 1 gram

Hydro .375 gram

Stain Remover .25 gram

SWL .15 gram

STEP 4: Requirements for dyeing

Colors (Vary)

Chemicals 0.15 gram

DFT .2 gram

STEP 5: Requirements for printing

Color 687.5 gram

Chemicals 687.5 gram


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Gum 41.25 gram

Water 875.00 gram

Material Receipt Procedure:

Whenever the material is received from the suppliers the security checks the invoice (challan)

& records it in the inward register.

This is then notified to the concerned store manager who verifies the quantity of materialreceived & records it in his inward book.

The informationlike the name of item & its rate quantity is recorded in the stock register.

People from the quality control department check the quality of the received materials

through the various methodslike laboratory testing.

If the quality isacceptable the challan & billsare sent to the purchase department to continue

with the further process of materials.

Rivaa Expots doesnot purchase the grey cloth. The customerssend their owngrey cloth to

them. When the grey cloth is received in the company premises the quantity is counted.

Then the material is marked customer wise, giving the date of receipt, customers name,

givinglot no., etc with the marker. Same information is then recorded in the material inward

register.

The grey cloth is thensent to the grey cloth store. The company canstoreabout 15 to 20 lac

meter ofgrey cloth in theirstores.


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Material Issue Procedure:

Material issued from the factory isgenerally the finished fabrics orany equipment going out

for repairing. In fabric case the security man daily counts the finished rolls while it isloaded

in the tempo and makes the report regarding this. Also person from excise count the rollsand

prepare the different report. When these reports are prepared they are shown to senior

managerand when theygive greensignal then only fabricsare send out of the gate. Ifany

material is to be sent outside for repairing first it is confirmed by the security with the

concerned engineerand further he notes it in his report book which finally is dispatched to

the manager.

Material issue procedure isassimple as the receipt whenany material is issued from the store

by the store keeper for production use it is issued on the basis of the requirement of the

material signed by the supervisor. On issuing the entry of outward is made in the book

against which the quantity, quality,name of the machine on which it isgoing to be used is

mentioned. Assimilar to receipt procedure, even the issue of the material is mentioned on

computersystem.

Purchase Procedure:

The time, quantity, buyer and other factor plays important role in efficient purchase

procedure. If everything goes right it helps a lot to firm to increase its profitability. The

purchase procedure is explained inshort below.

As we have studied the head of colourstore and maintenance store preparesstock register by

them. Theyare the best person who knows regarding the available stock of particular material

and its daily usage. They better know when to re order particular material. They weekly or

sometime daily prepare a report regardingshortage of materials. Theyalso checkany pending

order is made forsuch product ornot and present the report before the general manager.


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If the same supplier is to be continued the manager informs the head of that department i.e.

either colour or maintenance store regarding this. If the supplier is to be changed he will

himself decide who will be the supplierand at what rate it will be purchased. He mayask for

quotation from new supplier ornegotiate further with the existingsupplier. Finally he informs

the head regarding the changesand finally head orders the supplier on telephone according to

requirement.

Once the order is received, whether bynew or old supplier, quality checking is done to ensure

that the received material is of desired standard. If the order isaccepted then challan issent to

the finance department for bill payment. And if inany case order is rejected,goodsare sent

back to the supplier for replacement.

Inventory Control System:

For any production unit it is very important to maintain stock at the optimum level.

Inventory stockshould not exceed after some extent so as to maintain the working capital

balanced and also it should not be too less to meet production requirement. In Rivaa Exports

they do not keep the inventorylevel for more than 15 daysstock in order to manage working

capital.

Inany dyeing or printing unit inventoriesare the fabric instock whether unprocessed, work

in process or finished fabrics, colour store and maintenance store. It is not an easy job to

controlsuch huge stocksand get it easily on time. In Rivaa Expots various departmentsare

made for thisand there byassign a head who carryall the responsibility regarding various

stocks.

Fabrics

Whengrey enters the factory first step is each roll ofgrey is marked with lot number and

partyname to identify the roll. So it is very difficult that any roll is misplaced. Also, after


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each process there isa particular department where the fabricsare kept after that particular

process.

In textile market, rate of P.O.Y., Yarn,and ultimatelygrey fabrics keeps on fluctuating. So

during recession period what customer does is they purchase huge amount ofgreyand loads

it in the mill, but do not give programme for it. At such situation the place where grey fabrics

are kept is blocked. So what they do is theystart the production processand complete it till

the fa bric is dyed or bleached and pass through stenter. There is special department called

white department at different places in the factory where such half processed fabricsare kept.

These departments are very clean coated with wooden carpet and fabrics are well covered

with plastic covers to keep it dirt free.

Colour store

Colour store is the place where the all the colours and chemicals are kept. There are two

departments of colourstore one where the coloursare actually issued and the other is where it

isstored. When the firm purchases the colours or chemicals it is kept instore only.

There is 1 stockist and 4 helpers working in this department pershift. As coloursare the main

raw material of any printing house their stock must be managed efficiently. Head of this

department and his assistants take care of the stock. They maintain a strong stock register

which is daily updated according to days issue. The coloursare issued onlyafter receiving

receipt signed by the assistant master. This receipt contains detailslike name and quantity of

material.

Also they continuously report to management regarding the position of stock or if some

materialsare required to re orderagain. Theyalso keep eyes on expiry date of each material,

ifsome materials expiry date is comingnearby and it is remain unused such materialsare

returned to the supplier before time so that company can be saved from unexpected loss.


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Maintenance store

In maintenance store spare parts of machines,stationery items, electric equipmentsand other

physical equipment which are required continuouslyare stored. Here also astock register is

prepared where issue or receipt of any item is noted down. From the stock register book

available quantity can be known any time. Here when the material is issued no receipt is

received because it isnot possible to issue receipt forsmall items like pens etc. so forsuch

items they asked for old used item or for expensive item they ask the head of department

where such material is to be used. This method helps the employees to become more careful

regarding materialand ultimately helps the firm from nominallosses.

Different Records Kept In Store:

There are three separate storesat Rivaa Expotrs Ltd.

y Colour/chemicalstorey Maintenance storey Finished goodsstore

The major function of the stores is:

y Receipt of materialsy Storage & maintenance of materialsy Issue of materials

Each store hasa manager who regulates the working of the store. Followingare the records

kept by the store manager:

Material Inward Register:

Informationabout the material received, its quantity, time of receipt, itssupplier is recorded

in this register.


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Item wise stock register:

Opening balances, closing balances, issue, receipt, wastage, etc of different items kept in

store are recorded separately in the stock registers.

Inspection reports:

The quality, quantity of different items in store is checked & recorded in the inspection

reports.

Purchase Indents register:

The items required by the store department are requested from the purchase department

through the purchase indents.

Material issues register:

Informationas to what material is issued to which department & their quantities, purpose are

recorded in this register.

Gate-pass register:

When finished goodsare dispatched to the customers,gate pass is prepared & is maintained

in the gate pass register. Gate pass isalso knownas invoice.

Pending purchase order book:

This register includes informationabout all the pending orders with the suppliers.

Types And Classes OfMaterial-Handling Equipments:

Material handling is defined as controlled movements of materials, from receipt through

storage & production and up to shipment of finished products. A proper material handling

system ensures proper movement of raw material,spare parts, work in process inventory, by

products, waste materials, finished goods from one location to another within the factory


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premises. It also covers the storage of materials in the factory premises. The external

movement of materials is covered under the discipline called logistics.

Rivaa Exports uses manual as well as semi manual material handling equipment for the

movement & storage of materials.

They use the following equipments for movement of materials:

Trolleys Rollers Lorries Pipelines Handcarts

They use the following equipment forstoring the materials:

Steel racks Cupboards Barrels & Tanks

There are different types of equipments used to move & store different types of material. The

classification of the various handling equipment are as follows:

As per form of material:

Trolleys, rollers, Lorries, Handcarts, Racks & Cupboards for cloth & spare parts. Pipes, barrels, tanks for water,acids, chemicals & dyeing colour. Pipelines & cylinders forgas & steam.

As per path of movement:

Handcarts,lorries, trolleys for movement ina variable path. Pipelines for fixed movement. ( vertical or horizontal)

As per degree of automation:

Rollersare semi automatic equipment. Hand carts, Lorries & trolleysare manual equipment.


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As per the purpose:

Racks & cupboards are used for the storage of spare parts, electronic items,stationery items etc.

Cylinders forstorage ofgas. Barrels & tanks forstorage of chemicals, dyes,acids, water etc.

As per the destination of transportation:

Trolleys, Lorries & handcarts are used to move semi-finished material or finishedmaterial from one department to other department within factory premises.

Classification OfInventories According To Abc Analysis And Ved

Analysis:

Any company has to keep substantial levels of inventories of all types to ensure that the

business processes are carried out in a effective way. But controlling all inventories

simultaneously is very difficult. Hence, the inventoriesare divided into many classes,so that

each division is properly administered. There are many different classification theories

develop like ABC analysis, VED analysis, FSN analysis, etc.

Rivaa Exports is basically dyeing house. It isa huge unit & it keeps large inventories ofall

the items, as it cannot afford production loss. Inventories at Rivaa Exports include dyes,

chemical, colours,spare parts, electric fittings,lubricants & oil, etc.

Classification as per ABC analysis:-

It is properly knownas Always Better Control. According to thisapproach there should be

a differential treatment for various classes of inventories on the basis of its monetary value.

This monetary value is consumption value of various products. In most inventoriesasmall

proportion of item accounts fora very substantial usage whereas large proportion of items

accounts fora very small usage. ABC analysis based on the empirical reality,advocatesa


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selective approach to inventories into 3 classes according to the descending order of

consumption value of items.

class

% of

consumption

% no. of

items

A 65% 15%

B 25% 25%

C 10% 60%

Classification of inventories as per ABC analysis is as under:

Disperse dyes are main dyes used; dyeing chemicals like soda ash, caustic, K-T,formic acid, hydrochloric acid, M.C.L., etc; finishing chemicals like fibrocil, ciba

soft, C.M.H, etc & other chemicals like citric acid, liozen, soaps, etc are major

chemicals used & other itemslike fuel ( lignite, coal,gas) & electric fittings, bearings

are put in A class & their purchases are highly procedural. They are purchased

from more than one supplier. Their inventoriesare not allowed to increase overaset

level. A class of itemsare those items who contributes 65% in consumption value.

Dyes like cationic dyes, pigmentsare used at a lower level, washing chemicals likehydro caustic,acidic acid, soaps, etc; general chemicals like poly thread, sodaash,

M.T, H.T, etc are used relatively at lower level. Other items like bolting cloth are

placed in B class. Spare parts of machines are also placed in B class. These are

those items who contribute 25% in terms of no. of items & there value wise

contribution isalso 25%.

Whereas water, coal, few lubricants & oils, valves, V-belts, pipe fittingsare placed inC class. It has 60% ofno. of items but their value wise contribution is only 10%.

Now here at Rivaa Exports, water & coal is the main item which is used in the production

process. Without them the production isnot possible. Since both of these itemsare available

at very cheap rates & hence they are placed in C class, but it is very important from

consumption point of view. So we can use another classification to divide the inventories

properly.


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Classification As Per VED Analysis:-

According to VED analysis the inventoriesare classified into 3 classes called Vital (V),

Essential (E), Desirable (D) items.

Following is the classification of inventoriesaccording to VED analysis:

y Vital items:- Theyare those items without which production willstop instantly. Theyare disperse dyes, finishing & dyeing chemicals, water, coal, diesel, fuels, etc are

considered as vital items.

y Essential Items:- They are those items without which production may not stopinstantly but there can be problems like slow down of production. Theyare bolting

cloth, washing chemicals, cationic dyes,gums,lubricants; pigments, etc are essential

items.

y Desirable Items:- No itemsare generally placed in the desirable categories,as theyare omitted & alternate usesare developed out of essential items.

Maintenance Planning System:

Maintenance planning is very important part forany production unit. Forany production unit

production loss due to breakdown of machines is veryshameful part. It isnecessary that all

machineriesare taken well care and serviced regularly in proper manner. In Rivaa engineers

give enough importance to maintenance planning which ultimately increasess the life and

resale value of machineries.

In Rivaa there is a special team of engineers and their assistant who handles all activities

regarding maintenance. These engineers are very efficient and have a vast knowledge


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regarding the machineriesand their parts. There are two teams of engineers havingseparate

workstation, one for dyeing machineriesand other for machineries related to printing.

While maintenance work the machineries is to be shut closed, so time planning for

maintenance isalso important. It should be seen that there should be minimum production

loss due to maintenance. There is one day off every week for maintenance purpose. On

Saturdaystaggering occursso maintenance day is kept on that day.

In Rivaa the system for maintenance is very logicaland efficient. There isa register in the

workstationarea where anyone can write the complaint or problem regarding machine in it.

So operator orassistant operator of machines writes their evensmall problem in that register.

Then the engineersstudy it continuouslyand plan his maintenance work. If he cansolve the

problem immediately without interfering in production process, he solves it at the same time.

If the work is very complicated or time consuming he solves it on the day ofstaggering.

Beside this engineers have their fixed routine workalso during which they do routine services

and check up of each machines whether any problem is registered or not. During the

production process, emergency occurs due the breakdown of the machinery that is to be

repaired immediately otherwise can result into huge production loss, at such time the

maintenance department playsan important role.

Records Related To Production Operations At Different Machines:

Beinga production unit Rivaas mainaim is to earn high production. For huge production

capacity it is not easy to maintain records related to production operations. But it is to be

maintained in order to control production capacity, cost and ultimately profit of the firm.

It is very important in the cut-throat competition to provide competitive price to the

customers, for this it is necessary to control cost of production which is possible only by

maintaining records related to competition. Here managers have designed various for

different machines from which easily all the required information can be known regarding

units of production, time taken by it, time duration of machine not operated and reasons for it.

For every machine different report is designed which isshown below.


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All this reports are prepared by the supervisor or assistant master on daily basis, and is

checked by managersand director of company. Actual production can be known from this

documentsand production capacity can be controlled. Forany queries directors consult with

masterand try to solve the problem.

The format of the various reports generated is as follows :

1. DRUM:

SR NO. DRUM

NO.

PIECES QUALITY REMARKS TIME

IN

TIME

OUT

REPORT:

REPORT:INCLUDES REASON FOR PROBLEM OR BREAKDOWN ON

MACHINE.

By preparing this report one comes to know when and how many batches of grey are

processed. It also includes the reason forany time delay or time gap between two batchesso

that if there anyserious problem then the manager can take any beneficialstep for betterment.

2. JET MACHINE:

SR.

NO.

QUALITY PROCESS PIECES METERS TIME

IN

TIME

OUT

REMARKS


MACHINE.

REPORT :

REPORT :


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3. STENTER :

STENTAR NAME: SUPRA

SETTING

FOR PRINT

DRY FOR

PRINT

SETTING

FOR DYED

FINISH

PRINTED

FINISH

DYED

FINISH


MACHINE.

This report helpsalot to find out how many meters of printed or dyed are getting finished or

setting is done. It helps to know that in how many hours what metersare getting produced

and what should be the speed ofstentar to increase production.

REPORT :


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orsupervisor if they want drumming effect or not. But in certain quality of fabrics it is

necessary for better feeland flow.

Drum machine is the large structure like a watergeezer. It is horizontal cylindricalshaped

equipment consist ofstrong rectangular box inside. In drum machine the cloth is put for 6

hours, 2.5 kg pressure isgiven in the machine and the temperature of water in machine is

130 centigrade. The steam pressure comes from boiler. It automatically releases steam

when the pressure is very high in the machine like pressure cooker. The other purpose of

drum machine is to reduce the weight of the cloth. Caustic and various swellingagent,

stain remover is the chemical to which the task is done.

The total production of the drumming machines isapprox 35000 per day.

4.Jet Machine:

Grey cloth is manufactured by weaverand sold to different partiesafter that it reaches to

factory, between the two tasks there are lots of procedure, which have to carry out and in

those procedures the cloth,gets dirty. There are so manystainsand different types ofspots

and other chemicaland physical imparities on the cloth. So Jet machine removesall the

dirtiness of the cloth and converts the color in to optical white which is knownscouring

process. And then clothesare dyed in the same machine. Different dyesand chemicalsare

used for this process. Also the main work of jet machine is weight reduction. It removes

the oil from the grey which is to be put while weaving the grey.

Jet dyeing machine is long and cylindrical sha pe. There is U sha pe jets dyeing

machines. There isalevel recordinggauge just near the bottom of machine which records

the level ofliquorspeed. In Rivaa Exports Pvt. Ltd there are 14 jet machinesand theyall

are continuously performing the work on daily bases. In jet machines temperature is kept

between the 80 and 130 C and the pressure is kept between 2 3 kg.

The process time is 6 hoursand during each process 24 to 48 rollsare processed depends

upon the size of machine (i.e. capacity for big machines it is 180 kgs, 100-110 kgs for


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small machines) and programme of master. In jet dyeing machine the cloth is dyed inall

dark or light colorshades but as majority of fabrics comes for printing purpose most of

the fabrics is made white in colour, as white is the best base colour in printing. The

chemical used depends upon features of fabrics. For different fabrics different chemicals

in different quantity is used. Jet machine is the central machine in dyeing process house.

In order to achieve good dyeing result normally four types of energiesare utilized:

y Chemical i.e. the dyestuff which is required a chemical for dyeing.y Thermal i.e. high temperature.y Fluid energy i/e/ circulation ofliquor.y Kinetic energy i/e/ rotation of material.

Detailed process of jet dyeing isshown below:

1. Loading: In this process Jet Dyeing machine is filled up with waterand thereafter thecloth is in jected into the machine and finally the two ends of cloth are tied up and

machine lid is closed.

2. Washing: In this process the cloth inside the jet-dyeing machine is washed with coldwater. There are basically two processesadopted for the washing.

a) Running wash: In this process the fresh water is in jected from the top of jet dyeingmachine and isallowed to throw out from bottom fora period of 15 to 20 mins. In this

process mainly the impurities present on the cloth surface is removed.

b) Batch washing: In this process the cloth is washed with water filled in the jet-dyingmachine for period of 5-10 minutesand this water is removed. Again the jet-dyeing

machine is filled with waterand washing is done. This process consumesless quantity

of water.

3. Scouring: In this process hot alkaline liquor is circulated under pressure of 2-3 kgs for30-45 minutes. At thisstage the temperature is maintained up to 130C. In thisstep

solventsare removed from the fabric and weight reduction takes place. The chemicals

added in this process are like Hydro sulphide, caustic soda, deformers etc. After

scouring thisliquor from the machine is drained out and again running wash is done.

4. Washing: Same processas instep 2 is repeated.


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5. Acid wash: In thisacid isadded along with waterand steam is introduced inside thejet achieving temperature up to 100C. At this temperature cloth is kept a bout 15

minutes and thereafter the wastewater from the jet-dyeing machine is discharged.

After this process the cloth is ready for dyeing.

6. Dyeing: In thisstep dye of required colorsare added in the jet dyeing machine withfresh water along with other chemicals like leveling agents, deformers, swelling

agents,softeningagents, dispersingagents etc. This mixture is then heated up to 105-

130C and this temperature is maintained constant up to 15-30 minutes. This batch is

then cooled up to the temperature of 90C and thereafter discharged.

7. Washing: After dyeing operation, the cloth is washed same asstep no 2.8. Acid wash: same as point no. 5.9. Unloading: The cloth is removed from jet dyeing machine for transferring to the heat-

setting machine.

The total output ofall the jet machines isaround 55000-60000 meters per day.

5. Stenter:The purpose for which cloth is put in the stenter issettingand finishing of fabrics. In other

words, ironing of fabrics. The stenter machine is the main machine of a firm carrying

dyingand printing processes. The grey is laid in the sheet from over the roller into the

machine. The width of the grey is controlled bya photocell in the machine. The grey is

dried by high oil temperature ofabout 180-210 degree Celsius. The shortage of the grey

cloth is reduced so that the coloring may be done uniformlyand the grey properlyabsorbs

it.

Thus the basic purpose ofstenter is better finish, width settingand forsoftness. Before the

fa bric is pass through the stenter it pass from a open bucket which contains water and

certain chemicalslike amino Silicon for hard finish. After this, it passes from mangle,an

important part of stenter which squeeze water and chemical from which the fa bric just

passed then it goes through chudi roll, a heavy roller which stretches the cloth for

temporary removal of curls then it passes through chambers ofstenter for heat setting. Just

before it enters in the chamber there is a transitory photo cell which automatic set the

width of the cloth according to programme set by the operator.


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A stenter processes 80,000 meters of cloth daily for the firm. The grey after being

processed in the stenter machines is set for printing. In certain cases the parties order

only for dying, for them the final product is ready. .

There are 2 stenters in Rivaa Exports Pvt. Ltd. both of which are of 4 chambers. For best

utilization of the resources and equipment and to reduce the cost per unit at this

competitive edge, machinesshould be used at there maximum capacity.

6. Printing Machines

Printing process has to carried out with following 4 steps

y Preparation of designand deciding colour combinationy Preparation ofscreeny Preparation of coloursy Printing of fabrics

Preparation Of Design And Colour Combination:

Printing process starts with the preparation of designs that are going to be printed on the

fabric. Designingnowadays have become the most important and the vital part of the fabric.

It is through designs only the masterapproves from the buyeraftershowing the whole range

of collection that he hasnewly developed and thus receives order. The designsare the heart

of fabric, so the master has a team of 6-7 designers under him, which includes both hand

artistsas wellas computer designers. The designing includes two types of designers:

1. Hand artists.2. Computer designers.

Before one decade, there were no computersso the designs were prepared by the artists with

their hand which was very time consuming and then it was replaced by computers which

made designing verysimpler. But now also there are some designs, which cannot be made as

sharp as the design made through computers.


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In this company, there are 3-4 hand artists. They make new designs everydayaccording to the

trend or any particular order after guidance from master. They also create by their own

imagination but finally the masterapproves them. They draw ona Kodak paper then theyare

traced or exposed through ultraviolet rays/lights on a big Kodak paper. After this they are

sent to the photography department who then transfers the design from that pa per to the

screen that is made of rectangularshaped closed rod, which is covered by bolting cloth. Then

after it is prepared then it goes to printing department. But sometimes these hand made

designs are also scanned into the computer and then it is edited and then finally sent for

screen preparation department.

Apart from hand artists there are 3/4 computer designers, who make new designs on

computer through software called Photoshop. The new designs are prepared by them but

nowadays the master buy sketches of designs from professional designers who regularly

develop new designs according to the prevailing fashion in the city. These designs are the

scanned by the designers and edited if needed then they are transferred to the screening

department for exposing of designs.

Screen Preparation:

After the designing process has been done, it is then transferred to the screening department.

Here screen is prepared in two ways:

y Photographyy Engraving machine

1) Photography:Ultraviolet rays transfer the design from that Kodak pa per to the screen, which is

made of rectangularshaped closed rod that isattached by bolting cloth on which the

blue chemicalnamed 999 isapplied before transferring the design. Then the next step

is that the screen is then exposed and then issent to the sampling for final testing on

the sample fabric. Ifapproved then it is passed to the printing machine.


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2) Engraving machine:

This machine has been replaced the photography process to make screens. This

machine was imported from Japans best company making textile machineries. The

machine is called ICHINOES MACHINE.This machine has the capacity to make 50-

80 screens in 24hrs. This is one kind of printing machine only. At first whenscreens

are prepared 999 chemicals isapplied on it. The next step is to print the design on the

screen with the hel p of machine. Then the screen is exposed on the table under

ultraviolet lights for 30 seconds. Lastly, the screen is kept in water for 20 minutes

after which it is kept undersunlight for final touch up.

Preparation Of Colours:

While finalizing the designs master also decide various colour combination of particular

design and accordingly informs his assistant regarding proportion of colours. Colours are

prepared in the colour kitchen,now the raw material for these coloursare same which can be

used in jet machines but finally those coloursare not used while printing. Coloursalso pass

through some process, in this process coloursare mixed with hot treated gum, which is very

thick and then kept it idle until it reaches room temperature. Here it very necessary to

maintain proper proportion of colours while mixing. The colours are now ready to use for

printing.

Printing Fabrics On Flat Belt Machine:

Now after the design,screenand coloursare prepared before printing workstarts fabricsare

passed through batchingstenter. Batchingstenter islike stenter only ofsingle chamber but at

last fabricsare rolled tightly over beam rod. This rod is kept just before the flat belt machine.

Flat belt consist of circular flat rubber belt, which movesaftergap of 5 seconds. On this belt

screens are kept which has normally 1-meter width. On most of the machines 10 to 12

screens can be kept i.e. 10 to 12 colour design can be made onsingle ongoing fabrics.


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According to designsscreenare kept on belt with support. Fabric is introduced through these

screens over the blanket. As the fabric is brought underascreen the screen is moved over the

cloth. The colorand design on the screen in thus obtained on the fabric and fa bric moves

ahead fornext screenand the processgoes on till the last screen comes. As the cloth passes

through the screens workersstanding by pulls the puller over the screenso that the marked

design prints on that part of cloth with one particular color. At the end afterall the screensare

used the cloth is passed through the dryer where the wet coloursare temporarily dried so that

different colours doesnot mixes with each other. The temperature of this dryer isaround 150

degree centigrade. After this process the coloursare required to permanently fixed for which

fixation process is explained further.

A printing machine printsapprox 10000 12000 meters per day.

7. Padding machine

In the locallanguage this type of dyeing is knownas padding process but actually it isnamed

as PAD DYEING. In this machine the grey is dyed. The same can be done in jet also but the

difference is that here two or more shades can be dyed in jet only single colour is dyed

uniformly but here onasame fabric 2 to 4 shades can be dyed. The process before and after

pad dyeing is same as the process before and after printing machine. For padding grey is

passed through batching stenter after it is bleached and finished properly. This process is

basically a hand process, a man continuously pours colours on the pad, which are thick

enough to merge each other,and other person spread the colours to the fabric to dye. This

person is very talented and professional and they are highest paid workers in the whole

factory. The quality of this process fully depends upon his capabilities. Like printingafter this

also fabricsare required to pass through fixation process, which is explained further.

The total production ofa padding machine isaround 13000 meters per day.

8. Fixation process

The purpose of fixation is to fix the colours permanently. The fabric after print or pad dyeing

passes through two processes for fixation of colours.


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y Loop agery Washing

Loop ager

After the cloth is dried in the dryer the cloth is taken near the loop machine, which is

collected, in the dry trolley. The main purpose of loop machine is to fix the colour and

remove the unwanted colour from the printed cloth. Loop machine is big rectangular box

where there is high temperature steam around 165 degree to 170 degree centigrade. It takes

one and half hour to generate such hot steam. Fabric is passed through this box slowly which

fixes the colours. At any time inside the box there is 250 to 300 meters cloth.

Total output of this machine isaround 24000-28000 per day.

Washing

The cloth is washed finallyafterall the above process for removing unfixed colourand other

impurities. For washing the fabric is passed through 10 tubs of water, which inlocallanguage

said as kundis. The descriptions of these kundisare given below.

y In the first three tubs there is cold water containingsoap. Here the unfixed colour isremoved from the cloth.

y In the next three tubs contains hot water with hydro caustic for the removal ofgumand other impurities.

y The next three tubs containacetic acid for bettersoftness in fabric.y And in the last tub plain water for removingall these chemicals.

After the fa bric is completely washed the wet cloth is put in the small machine to squeeze

cloth. These machinesare called hydro extractor. Now the fabric is ready for final finish. The

fabric then once again passes through stenter for finish and then through 0/0 machine forsoft

feel.

9. Zero Zero Machine :This machine is basically used for ironing the cloth before taking it to the packingand folding

department. After the cloth is passed to the zero zero machines the feel of the cloth

improvesand givesa betterlook.

A machine givesa production of 20000-22000 meters per day.


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10.Folding Machine

In Rivaa Exports Pvt. Ltd. there are 12 folding machines. This machine arranges the Grey

from rough form to unique form. It requires the cloth to be folded and packed properly in

order to carryand store easilyand efficiently. It converts the scattered fabric into folded roll

or taka. After the fa bric is folded the meter man counts the meter of each roll and note it

down on job card issued by excise department,also the finish meter is written down on the

rollas well. All the rollsare stored according to its roll in the finish department. These lots

are now ready to dispatch to its real owner. Capacities ofall folding machines are 60000

meters per day. Thus,after folding theyare delivered the next day to the customers.

ListOfPlant & Machineries:

Sr.

No.

Name of Machinery No. of

Machin

es

USE

1. Stenter Machines (Total 8 Chambers) 2 WIDTH SETTING,IRONNING & FINISH

2. Printing Machines (Automatic with 12 printable

color)

3 PRINTING FABRIC

Printing Machines (Semi Automatic with 12

printable color)

2 PRINTING FABRIC

Printing Machines (Semi Automatic with 17

printable color)

2 PRINTING FABRIC

3. Rotary Printing Machine 1 PRINTING FABRIC

(CONTINUOUS SINGLE

PRINT)

4. Jet Dyeing Machine of 250 kgs 6 SCOURING/DYEING

5. Jet Dyeing Machine of 80 kgs 6 SCOURING/DYEING


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6. Jet Dyeing Machine (long tube) of 300kgs 2 SCOURING/DYEING

7. Boiler (Coal fired) each of 5 ton/hr. 1 STEAM GENERATION

8. Universal Loop Steamer 2 STEAM FOR COLOUR

FASTNESS

9. Batching Machines 1 BATCHING

10. Drum Washer Machines of 300kgs 3 TO OPEN YARN

(MAKE GREY READY FOR

PROCESS)

11. Drum Washer Machines of 100 kgs 2 TO OPEN YARN

(MAKE GREY READY FOR

PROCESS)

12. Folding Machines 4 FOLDING OF FINISHED

FABRIC

13. Padding Machines 2 DYEING IN STRIPE FORM

14. Zero Zero Machines 2 SOFTNESS

15. Ager Machine 1 STEAM FOR COLOUR

FASTNESS

16. Diesel Generator Machines 4 POWER GENERATION

17. Compressors 6 AIR PRESSURE

18. Flatbed Screen Engraving Machine 1 CREATE DESIGNS

19. Delivery Vans 3 FOR PICK AND SEND OF

GREY N FINISHED GOODS

project repot - rivaa exports

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