CHAPTER-1

INTRODUCTION

Cotton, the primary crop of economic importance was placed in high pedestal way back
in early 1921 with the Indian Central Cotton Committee sponsoring cotton research (ICAR)
launched the All India Coordinated Cotton Improvement Project (AICCIP) in the year 1967 with
its Headquarters at Coimbatore (Tamil Nadu) to give new thrust and direction in terms of multi-
centre approaches with the active involvement of State Agricultural Universities across cotton
growing state.

Currently, the AICCIP Project is in operation with its Headquarters at Coimbatore and
spread over 21 participating centers involving 16 state Agricultural Universities. The Central
Institute for Cotton Research (CICR, ICAR), Nagpur and its Regional Stations at Coimbatore
and Sirsa provide basic research support and also take part in some of the strategic research and
evaluation activities of the AICRP on Cotton.

The Central Institute for research on Cotton Technology (CIRCOT, ICAR), Mumbai and
its Regional units are closely associated with AICCIP in assessing the fiber quality parameters of
cotton cultures under trial. Major activities of the centres include development of varieties and
hybrids best suited for different agro-climatic zones, development of viable and economical
agro-techniques for realizing maximum yields from improved cultivars besides development of
economic and effective pest and diseases management practices under different agro-ecological
conditions.

In addition, the cotton breeder seed production is also monitored through AICCIP.

1
 1.2 AN OVERVIEW OF A COMPANY

COTTON SPINNING MILS- AN INTRODUCTION

Food, clothing and shelter are the basic needs of human beings. The requirement of cloth
to the human beings is to protect themselves from light, wind and rain. The vision of the
manufacture of clothes was sophisticated. The cotton spinning and weaving and cloth
manufacturing were always emphasized in India. Indian historical evidence testifies this. Large
number of handloom units was established in 1600 A.D.

The activities of handloom industry range from ginning and spinning, weaving, reeling
and cotton manufacturing. In the olden days this handloom activity was popular in villages and
workers used to manufacture high quality and attractive products that enjoyed market widely.
Infact, the handloom products exhibit the skill of workers engaged in the industry.

The handloom industry in India is, by far the largest cottage industry with having high
employment potential. It provides employment to millions of artisan weavers and is only second
to agriculture in providing livelihood. The Grasamer silk of Varanasi, fine Muslim of Deccan
and Patola of Baroda and other fabrics of

 ANDHRA PRADESH,
 ASSAM,
 KARNATAKA,
 MANIPUR,
 ORISSA and
 TAMIL NADU have been famous of ages.

The advent and growth of spinning mills forced the weavers gradually to leave the
traditional weaving occupation and take-up mill made cloth occupation. However, weavers
became idle and unemployed.
2
 1.3 EVOLUTION OF COTTON INDUSTRY

The cotton textile industry is one of the well-organized industries in our country both in
terms of value of annual output and number of labourers employed. India has world’s highest
land acreage under cotton, but in terms of production among 55 major countries, it ranks fourth
after the U.S.A, Russia and China. The cotton industry accounts for 20 percent of total industrial
output, provides employment to 20 million people and contributes to 30 percent to total value of
exports.

The cotton textile products have become indispensable for all sections of people through-
out the world. The Industry has been emerging as a highly organized one in almost all countries
today. In fact, many countries have made a significant progress in manufacture of cotton textile
products. In order to provide adequate clothing to the growing global population, several
countries have been going in a big was by taking more land under cotton crop cultivation and
thereby to increase the production and productivity in the cotton textile [Link] is known
to be the home of cotton fabrics since the vedic times. Cotton fabrics and popular dress material
as well as utility apparel for the people of India, primarily because of the country’s tropical
climate. Even before the Christian era, the ports of the red sea know about the magnificent
velvets, silks, and cotton fabrics of India.

The Indian color combinations of bright and deep impressions with flowery designs and
prints of gods and goddesses were the most attracted and highly appreciated textiles throughout
the world. Hence the Indian culture and heritage was spread far and wide and shared by many
around the world. Several foreign economists, historians and Philosophers paid glorious tributes
to the beauty of Indian textiles. Subsequently process was made dyeing, bleaching, printing,
calendaring and mercerizing in the complex by gradually adding up of in the composite mills
located in Bombay and Ahmedabad. The textile Industry continued to be the largest industry in
India. It accounted for 20 percent of total Industry output, provided employment to 20 million
people and contributed nearly 30 percent to the value of exports in the year 1964.

3
PRODUCTION

India is the second largest producer of fiber in the world and the major fibre produced
is cotton. Other fibres produced in India include jute wool, and man-made fibers. 60% of the
Indian textile Industry is cotton based. The strong domestic demand and the revival of the
Economic markets by 2009 has led to huge growth of the Indian textiles industry. In December
2010, the domestic cotton price was up by 50% as compared to the December 2009 prices. The
causes behind high cotton price are due to the floods in Pakistan and China . India projected a
high production of textile (325 lakh bales for 2010 -11) There has been increase in India's share
of global textile trading to seven percent in five yearThe rising prices are the major concern of
the domestic producers of the country.

 Man Made Fibres: This includes manufacturing of clothes using fibre or filament
synthetic yarns. It is produced in the large power loom factories. They account for the largest
sector of the textile production in India. This sector has a share of 62% of the India's total
production and provides employment to about 4.8 million people.
 The Cotton Sector: It is the second most developed sector in the Indian Textile industries.
It provides employment to a huge number of people but its productions and employment is
seasonal depending upon the seasonal nature of the production.
 The Handloom Sector: It is well developed and is mainly dependent on the SHGs for
their funds. Its market share is 13%. of the total cloth produced in India.
 The Woolen Sector: India is the 7th largest producer. of the wool in the world. India also
produces 1.8% of the world's total wool.
 The Jute Sector: The jute or the golden fibre in India is mainly produced in the Eastern
states of India like Assam and West Bengal. India is the largest producer of jute in the world.
 The Sericulture and Silk Sector: India is the second largest producer of silk in the world.
India produces 18% of the world's total silk. Mulberry, Eri, Tasar, and Muga are the main
types of silk produced in the country. It is a labour-intensive sector.

4
JUTE TEXTILES

 India is the largest producer of raw jute and jute goods and the second largest
exporter after Bangladesh. There were about 80 jute mills in India in 2010-11, most of
which are located in West Bengal, mainly along the banks of the Hooghly River, in a
narrow belt (98 km long and 3 km wide).

 In 2010-2011 the jute industry was supporting 0.37 million workers directly and
another 400,000 small and marginal farmers who were engaged in the cultivation of jute.

 Challenges faced by the industry include stiff competition in the international

market from synthetic substitutes and from other countries such as Bangladesh, Brazil,
Philippines, Egypt and Thailand. However, the internal demand has been on the rise due
to Government policy of mandatory use of jute packaging. To stimulate demand, the
products need to be diversified. In 2005, the National Jute Policewas formulated with the
objective of improving quality, increasing productivity and enhancing the yield of the
crop.

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1.4 MINISTRY OF TEXTILE INDUSTRIES

The Government of India passed the National Textile Policy in 2000. The major
functions of the ministry of textiles are formulating policy and coordination of man-made
fiber, cotton, jute, silk, wool industries, decentralization of power loom sector, promotion
of exports, planning & economic analysis, finance and promoting use of information
technology.

6
 1.5 COMPANY PROFILE

Name of the Company : Arul Industrial Estate Private limited.

Date of Establishment : 1968

Date of Incorporation : 11 october 2006

Register Number : 13138

Address : M G R Nagar, Arulpuram, Tiruppur,641605.

Name of the heads : A . Velusamy

E-mail : yarn@[Link]

Class of company : Private

Company sub category : Non-govt company

Activity : Spinning, weaving and finishing of Textiles

Listing Status : Unlisted

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1.6 VISION AND MISSION

“Quality”- maxim of SKY COTEX SPINNING MILLS PVT LTD.

VISION

 Ensuring a strong presence in textile globally.

 Market by focusing on exceeding and quality.
 Keep up to the customer and stakeholder expectations.
 To have strong presence in the global apparel market in terms of brands, ethics, values
and principles with core competence in fostering customer aspirations.

MISSION

 Offers innovative, customization and value-added services to the customers stakeholders,

employees and society.
 Constant upgradation of technology and skill sets to Carter to the ever-changing needs of
the textile industry.
 To become a process driven organization and to be ethical, transparent and responsible
organization.
 To prevail as the most preferred one-step source for readymade knitting garments, yarn
and fabric.
 Leveraging art, design and technology to deliver quality products and being environment
responsible in all the process.

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7 KEY RESULT AREAS AND ITS ACTIVITIES:

1.7.1 HUMAN RESOURSE DEVELOPMENT

 Encouraging the employees by giving incentives to reduce absenteeism and increase in
employee satisfaction by providing the basic necessities.
 Decrease in workplace accidents by providing well equipped Health & Safety measures.
1.7.2 MARKETING & MERCHANDISING
 Have followed multiple calculative measures on garment in order to cut down the
additional cost.
 Convincing the customer on the actual scenario of the market and getting the required
upcharge on every possible means.
 Getting the year-long order quantity will help average the costs and increase the
overall profit.
 Updating the customer with the new innovative products & fabric development and
getting orders with better margin.

1.7.3 FINANCE & ACCOUNTING

 They work closely with the Govt bodies and submit all the relevant documents to get the
subsidiaries availed by the govt.
 They do the payment in advance for all the suppliers and negotiate with them for
discounts.
 They work on the P&L and submit the report to the top management so that they can
make themselves aware of each depts progress.
1.7.4 EXPORT LOGISTICS
 They do the negotiation with the transporter and fix the costs on yearly basis.
 They keep in track of the import & export duty benefits and make the most of it and cut
down the overall expenses

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1.7.5 QUALITY TEAM
 Maintaining quality rating.
 Perfect delivery rating.
 They train team for inspecting the goods to customer requirement and get the nomination
and cut down 3rd party inspection charges.
 They are trained up in such a way that they do R&D on their own and have cut short the
R&D development costs.

1.8 KEY STRENGHTS

SKY COTEX SPINNING MILLS PVT LTD Mills is Close to 4 Decades of Rock-Solid
Experience and has Location Advantage with rich experience in Textile and Apparel industry,
located near Tirupur – Asia’s Largest Knitwear Cluster. Has impressive product range that
focuses on unique customer products. Quality is assured in every aspect and has best
infrastructural advantages like strong and dedicated workforce, trusted client base, both National
& International, and Substantial self-sufficiency in power needs through green power generation
by windmills.

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 CHAPTER-2

2.1 ORGANIZATIONAL CHART

An organizational structure is a system that outlines how certain activities are directed in
order to achieve the goals of an organization. These activities can include rules, roles, and
responsibilities.

The organizational structure also determines how information flows between levels

within the company.

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 ORGANIZATIONAL CHART

Managing
Director

Production General
Manager Manager

Supervisor Sales Accounts Purchase

Company’s
Department

Factory Storage
Department Purchase
Outlet Department
Employee

12
 The organizational chart of the sky cotex spinning mills consists of two
partners in the top organization who takes care of all the activities in the organization.
Under them there are five major departments which converts the raw boards into
finished furniture. The departments are

 Purchase department
 Storage department
 Production department
 Quality control
 Accounts department

The purchase department consists of the purchase head and an employee

to take care of the goods purchase and to carry forward the goods to the next level .

The storage department consists of one supervisor to look after the storage
of clothes and the maintenance of the clothes. It consists of some labours who are
there in time of help to separate the clothes and for dispatch of clothes.

The production department requires many employees to carry out the process as it
consists of various processes to transform the thread. Each process consists of at least one
labour for assistance and to carry out the process. There are additional employees and labours
who work on shift and timing basis of the work.

The quality control department consists of one main employee and one labour to check
the quality of boards. The low quality clothes are disposed then and there by the employee to
avoid malfunction in the process of assembling of clothes.

The accounts department consists of one main employee who takes care of all the
accounting processes with the help of all department supervisors. Mainly the accounts
department employee clarifies doubts directly with the partners of the company to avoid
misrepresentation of accounts.

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 2.2 FUNCTIONAL ACTIVITIES AND ITS DEPARTMMENTS

There are various departments to perform the functional activities and to transform the
raw material into finished goods. All these activities convert the plain cotton into cotton yarn.
It requires various types of hardware’s and machines to produce the cotton yarn. Skilled
labors are employed in the company to produce good cotton yarn which are supplied to nearby
Districts. The various departments are;

2.1 Processing

2.2 Purchase Department

2.3 Storage department

2.4 Production department
2.5 Quality control
2.6 Accounts department

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2.1. PROCESSING

The processing is located in same sky cotex spinning mills, which provides high quality
Solutions for Textile dying, printing and as well as finishing needs.

 Our production facility contains innovative and reliable systems to match up to all
levels of processing requirements.

 Talking an advantage of our in-house spinning, we offer a strategic advantage to

our customers of better quality products at a shorter lead-time.

 Daily 14 tons of various knitted fabric processed finished according to buyer

requirements

 Equipped with top of the line THESIS dying machine from Germany.

 Our finishing range is apt for both Tubular & Open width forms

 To cater to the growing demands of the top end apparel brands, we have been
continuously adding on new special value added products with relevant
performance finishes.

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  Finishing includes stenter frame EH-HWA from KOREA with MAHLO weft
straightener.
 LAFER compacting machine from Italy for both tubular and open with
requirements.

FUNCTIONS & RESPONSIBILITIES

 Planning on raw material purchase

 Checking production report on daily basis.
 Setting targets for each day.
 Responsible for the batch for which the style has to be installed.

2.1.1 FABRIC RECEIVED

It is the first factory process, after receiving fabric, it will be directly sent for dying and the
weight of knitted grey fabric is checked and passed to compacting process. After that the fabric
department will check the weight of the bale and it should be in maximum weight of 1333 kg. If
there is any weight loss in bale it will not be taken to fabric storage. If the fabric is approved, the
person in-charge will deliver the Challan.

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2.1.2 FABRIC INSPECTION

After receiving the fabric, it will be relaxed for few hours. There are two types of fabric relax:
Manual relax and machine relax. For manual relax they take 15 meters lap, if there are more
problems it will move to machine relax. Inspection of fabric is done to check out the fabric
shade, width, GSM, washing and shrinkage and is moved to fabric storage.

2.1.3 FABRIC REQUISITION

Fabric requisition will come from PPC (Production Planning Department) like meters
required and based on requisition the fabric is send to the cutting department. Fabric is relaxed
for few minutes on spreading machine. The spreading machine used in KPR mills are Erber,
Lectra and Fk. CAD department will prepare pattern by using lectra software. For marker
making, Modaris and Marker managing softwares are used.

2.1.4 CUTTING

The cutting department receives the fabric from the fabric department after inspection and
ensures 100% accuracy and quality in cutting and issues all the parts to sewing section. The
cutting floor is a combined unit for spreading, cutting, ticketing and bundling. The work of
cutting department starts after receiving order from the buyer by the merchandising department.
Two types of cutting includes, Auto cutting & Manual cutting

The CAD department prepares the marker using the patterns prepared by the Sampling
Department. It also prepares the CAD-Consumption Worksheet and makes estimation for the
consumption of the fabric for that particular order. The results are then communicated to
merchandiser.

2.1.5 CUT PANEL AUDIT

After cutting of the fabric, it is passed to cut panel audit for checking and proceeded for
barcode stickering.

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2.1.6 BARCODE TRACKING SYSTEM

It is a unique system practiced at Quantum knits to have better traceability of the production.
Each and every garment are Barcoded soon after cutting is done. The sticker remains till the final
packing. The barcode derives the complete tracking details such as buyer name, order number,
line in which it is produced, etc.,

2.1.7 BUNDLING AND LOADING TO TROLLEY

After stickering the bundle, all the panels are loaded to trolley and stored in input section, the
panel sends to embroidery department or printing department for embellishments and stores into
trolley again. If any stock is required for production, it’s taken from input section to deliver the
stock and they make delivery challan and trims likes button, zipper, sewing thread are taken from
trims store for that also store keeper makes challan to give trims.

2.1.8 PRODUCTION LOADING

Here loading labor will re audit the cut panel and make placket marking and pass on to
sewing process.

2.1.9 WEAVING

Weaving unit is located near Coimbatore, Tamil Nadu, in a working space of 2.2 lakh sq
feet. It specializes in manufacturing wider-width fabric upto 140 inches in the 500 TC to 1000TC
(thread count) range.

 We have 135 Sulzer wider width Jumbo looms and 18 Sulzer Airjet looms,
specially, capable of producing ultra fine count fabric in narrow/ Wider–width.

 we produce with 2,4 and 8 pick insertions, with maximum warp density of 110
ends/cm (280 ends/inch) with warp counts up to 100s Ne.

18
  Currently 18 Dobby looms have been specially modified for ultra fine count
weaving which are also in wider – width formats.

 85 jumbo looms capable of producing joint less rolls of 3000 meters in length
specifically meant for industrial textiles.

 Value adding in the future with jacquard looms for targeting high quality home
textile products.

2.1.10 SPINNING

 Unit – I with an installed capacity of 30,000 spindles which produces

around 25 tons of cotton yarn per day.

 Unit - II with an installed capacity of 1, 14,000 spindles which produces

around 65 tons compact yarn for knitting and weaving.
19
 Our major specialization is combed and compact knitting yarn where we
producing 65 tons.

 Equipped with spinning machinery from LMW Coimbatore, RIETER

Switzerland preparatory TRUTZSCHLER Germany etc

 .The complete spinning plant is installed with auto control humidification

system and waste collection system from blowroom to combing
departments. All the spinning frames are monitored by Ring Data System.

 Knitting yarn is sold in major consuming centers in India like Tirupur,

Kolkata & Kanpur.

 Around 40% of the production is exported to China, Bangladesh, Korea,

Philippines, Srilanka, Tunisia and European markets.

 The Company has been awarded ISO 9001: 2008 Quality Certificate
System by DNV Netherlands, and Social Accountability System SA 8000:
2008 by TUV,Global Training Method 5s certified by Quality Circle
Forum of India.

 The Company is also awarded as Export House by Government of India

for its export performance.

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2.1.11 KNITTING

Knitting Division started in the year 2009 is located in Coimbatore, Tamilnadu. It

products Grey Single Jersey, Interlock and Rib fabrics in diameter ranging from 20″ to 36″. The
Knitting Unit has the capability to produce 3, 00,000 meters of Knitted fabric per year.

 150 Knitting machines of Pailung and Mayer & Cie make.

 20 tons of grey knitted fabric production.

21
  We converting all type of knit construction, Viz, Single jersey, Interlock, Rib,
Pique flaw and other varieties.

 Auto Striper machines for yarn dye fabric.

 Flat bed collar knitting machines for full integration in-house.

 All machines with Spandex attachments.

 100% inspection of fabric rolls under 4 Points Inspection System.

 Flexible Machine Specifications – Dia from 20" to 36" -24/28GG.

2.1.12 SEWING

Sewing is the craft of fastening or attaching objects using stitches made with

a needle and thread. Sewing is one of the oldest of the textile arts, arising in the Paleolithic era.
Before the invention of spinning yarn or weaving fabric, archaeologists believe Stone Age
people across Europe and Asia sewed fur and skin clothing using bone, antler or ivory needles
and "thread" made of various animal body parts including sinew, catgut, and veins.

Basic Sewing METHOD

Step 1: Unravel and Cut. Start with unraveling the thread from the spool. ...

Step 2: Weave. Weave the thread through the loop on the one end of the sewing needle.

Step 3: Starting to Sew. Before sewing, you need to tie the end of the thread. ...

Step 4: Continue to Sew. ...

22
 Step 5: Tying the Final Knot. ...

Step 6: Final Cut.

USES OF SEWING CLOTHES

Sewers working on a simple project need only a few sewing tools, such as measuring

tape, needle, thread, cloth, and sewing shears. ... In addition to sewing shears, rotary cutters may
be used for cutting fabric, usually used with a cutting mat to protect other surfaces from being
damaged.

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2.1.13 PRODUCTS

YARN

Yarn is a long continuous length of interlocked fibres, suitable for use in the production
of textiles, sewing, crocheting, knitting, weaving, embroidery, or rope making. Thread is a type
of yarn intended for sewing by hand or machine.

Yarn is a package manager for your code. It allows you to use and share (e.g. JavaScript)
code with other developers from around the world. Yarn does this quickly, securely, and reliably
so you don’t ever have to worry.

Yarn allows you to use other developers’ solutions to different problems, making it easier
for you to develop your software. If you have problems, you can report issues or contribute back,
and when the problem is fixed, you can use Yarn to keep it all up to date.

Code is shared through something called a package (sometimes referred to as a module).

A package contains all the code being shared as well as a package.

Cotton and polyester are the most commonly spun fibers in the world. Cotton is grown
throughout the world. After harvesting it is ginned and prepared for yarn spinning. Polyester is
extruded from polymers derived from natural gas and oil. Synthetic fibers are generally extruded
in continuous strands of gel-state materials. These strands are drawn (stretched), annealed
(hardened), and cured to obtain properties desirable for later processing.

2.1.14 FABRICS

Natural fabrics are Cotton, wool, silk, linen, and jute, etc. Synthetic or man-
made fabrics are Nylon, Polyester, Spandex, Rayon, and Polypropylene, etc. Blended fabrics:
Polyester cotton, cotton, and wool, Cotton spandex, etc. Methods of producing fabrics Knitting,
weaving, etc.

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  Cotton. Most cotton fabrics are “pre-shrunk”, which makes them highly durable

 Synthetics (Polyester, Nylon, Spandex, etc.) ...

 Rayon. ...

 Linen. ...

 Cashmere. ...

 Silk. ...

 Wool.

The most expensive fabric in the world is wool, which comes from the vicuña
and can only be shorn from the animal once every two to three years.

Generally, a set number of yarns are used for the formation of fabrics. Also, a
number of techniques are used for producing fabrics such as weaving, knitting, and
felting. The type of fabrics varies by the fibres, the fabric formation techniques,
machinery used for producing them, and finishing techniques. Fabrics can also be made
differently based on the end-usage.

However, certain fabrics although uses a particular fiber 100% or uses a blend of
different fibers may be termed otherwise and are named depending on weaving patterns, texture,
and the processes, etc. such as Organza fabrics were often used to produce with Silk, but even

though they started using it with alternate fibers, it continued to be called as Organza Fabric.

25
TESTING OF YARN

Yarn test methods that are used when values such as tenacity, elongation or shrinkage
are determined.

 TEST ROOM CONDITIONS. ...

 LINEAR DENSITY. ...

 BREAKING FORCE AND ELONGATION AT BREAK. ...

 TENACITY (YARNS COUNT TENACITY) ...

 FORCE AT SPECIFIED ELONGATION (FASE) ...

 HOT AIR SHRINKAGE. ...

 HOT AIR SHRINKAGE FORCE

26
The manager receives the fabric and follows up and checks fabric thoroughly. Once the
inspection is done, garment is washed post production and inspected by the quality control
department and is stored in the storage area. The storage warehouse is equipped with the latest
electronic material handling systems for loading and unloading fabric which is stored. They have
separate racks to store organic fabric and each and every detail is entered in the ERP computer
system for easy tracking about fabric details.

TRIMS DEPARTMENT (Manager – Mr. Logesh)

Fig: Trims storage area

All trims such as labels, ribbons, laces, buttons, etc., are stored here and are issued on request
from the production team for the production flow. For every order bin card is followed which has
all the trims involved in particular order. Here heat transfer label and buttons maintained in
cooler place (+ or – 20-degree c). Non-PVC material used in heat transfer.

PRODUCT PROFILE

WOMEN (40%) MEN (30%) CHILDREN (30%)

Vest & Cami Vests Vest & Cami
Printed tees & hooded top shorts & boxers legging’s & shorts
Nightwear & pajamas’ printed tees & polo school tees & polo

MAJOR CUSTOMERS

M&S (U.K), GEORGE ASDA (U.K), DUNNES STORES (U.K), SAINSBURYS (U.K),
PRIMARK (UK), DECATHLON (FRANCE), KMART (AUSTRALIA), TARGET
(AUSTRALIA), H&M (SWEDEN), C&A(GERMANY), MAX (DUBAI), OVS (ITALY),
LIDL(GERMANY) LUCKY BRAND (USA), NAUTICA (USA), AND1 (USA),
27
COSTCO(CANADA/USA), WALMART(USA)

CERTIFICATIONS

ETI(SEDEX), ISO 9001 & 14001, OHSAS 18001, SA8000, WRAP, OEKO TEX, GOTS (FOR
ORGANIC PRODUCTS), ECO FACTORY STANDARD AND DISNEY APPROVED &
WAL-MART GREEN CERTIFIED, GMP APPROVED FACTORY.

MANPOWER PLANNING

Man power planning is also called as human resource planning as it plays a crucial role in
receiving maximum long-run benefits by carrying out the integrated plan of the organization.
This involves various tips

 Analyzation of inventory of present man power resources

 Estimation of the skill sets required
 Formulation of recruitment plan where they do advertising through Radio, word of
mouth, referrals and social media.

TRAINING MEASURES

In KPR Mill Limited, 30 days induction training is conducted for newly recruited employees
for analyzing their IQ level (i.e., 15 days theoretical training + 15 days practical training). The
employees are taught about company profile, government norms, customer details, nature of
work, company structure, management rules, technical training, and company regulations.

PERFORMANCE APPRAISAL SYSTEM

The performance of the employees is assessed every year for upgradation of the designation
of the employees. The seniority in their position is awarded for the workers those who possess
the following
 Open to continuous learning and Excellent performance.
 Loyalty to the company.

28
  Attendance percentage above expected and their ability in coping up with the situation
and acting accordingly.

PRODUCT PROMOTIONAL MEASURES

 They have their own domestic brand-named FASO and since they have been in the textile
market for more than 30 years, they have made lot of experiments in various products and
different fabrications and have LAUNCHED performance-based products competing
with top retail brands in India and have successfully made a startup already.
 They have hired leading branding & marketing consultants and have worked on various
promotional activities including various impressive hoardings in major cities.
 Also, in terms of export they have always been at top notch in terms of on time deliveries
with right quality which have been proven with top retailers across the globe and that
speaks as a promotional measure for their successful journey.

HRD MEASURES

 KPR provides employees with canteen, accommodation, medical and hygienic working
environment.
 All the safety precautions are taken by providing helmet, safety belt, shoes, ear plug,
safety gloves, apron and goggles.
 Provides best learning amenities for the workfolk recruited. SKY COTEX SPINNING
MILLS has tie-ups for higher education training programs with Annamalai University,
Alagappa University and Tamil Nadu Open University and close to 27,000 employees
have completed higher education during their employment.
 Infrastructural facilities like swimming pool, yoga and meditation classes, music classes,
auditorium for screening movies is provided for gratifying the workfolk.
 Basic insurance is provided for employees and at times of unfortunate accidental
situations, the employees can avail the insurance policy.

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EGO-FRIENDLY ACTIVITIES

 Effluent Treatment Plant (ETP) for waste water irrigation for 100% commitment to
environment protection with zero waste and zero pollution.
 Self-reliant in electricity production and has installed windmills that generate 61.92MW
power to quench 75% of SKY COTEX SPINNING MILLS power requirements.
 Taken initiative in planting more than 1,50,000 trees and promotes bio-gas generation by
cutting LPG.

2.2 PURCHASE DEPARTMENT

The purchasing department is similar to the sourcing department but the main difference
is that the sourcing department works for sourcing the fabrics alone while the purchasing

department works for sourcing the accessories and trims.

This raw material (raw cotton) is purchased and stocked for the production requirements.
The purchase department is otherwise called as raw materials department. Generally raw cotton
is purchased and received in the form of compressed bales. Generally a bale weighs around 170-
200 kgs. Normally in SSML they have a minimum cotton stock for three months and maximum
for five months. Price of raw cotton is calculated based on candy (1 candy is 355.5 kgs.). A stock
of 3 103 to 5 months requirement is maintained in SSML. There are five cotton departments in
the company and cotton is purchased by those departments from Rajapalayam, Pollachi,
Coimbatore, Maharastra, Andra Pradesh, Guntur, Singapore, etc.,

A quality plan is prepared by technical team and trial production is done. There is a
continuous and close follow up at every stage of production by Quality Assurance Department to
achieve consistent quality for which they have well equipped laboratory for quality assurance.
Production is based on well planned production plan to maintain shipments schedules.

The Company has a sound track record of productivity and profitability and has been
producing high quality yarn for the domestic market. The Company has also been regular in
modernizing its unit and at present almost all the machines at its existing units are fully
modernized. The Company's product range includes cotton carded and combed yarn in the count

30
range from 30s to [Link] company's products are well received in the local and international
markets.

TYPES OF PRODUCTION

1. Mass production: Manufacturing of discrete parts or assemblies using

a continuous process are called mass production. This production
system is justified by very large volume of production. Flow of
materials and components is continuous and without any back tracking
2. Make to stock production : SSML stocks the finished goods in
inventory for immediate delivery. This system ensures immediate
delivery of good quality, standard products.

2.3 STORAGE DEPARTMENT

The fabric and accessories stores department is centralized in apparel industry and all the
fabric and accessories comes to this unit first from the supplier and audited here and kept until it
is distributed to other units. For an export oriented and bulk production of Textiles industry. it
is essential to maintain a well-organized & well equipped inventory system. The main
responsibility of this department is to store all the raw material necessary to produce garments.
This department is sub divided into three sections. Store keeper follows a strong and appropriate
working procedure.

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STORE KEEPING SYSTEM

 Unload fabrics
 Inventory in warehouse.
 Fabrics inspection
 Recording in register book and Excel sheet.
 Updated information put in Bin Card

2.4 PRODUCTION DEPARTMENT

In every factory, production efficiency defends on some factors or parameters. As like as

other factory, production of Spinning mill defends on some factors.

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 Fig: Spinning mill (ring frame section)

Production is the functional area responsible for turning inputs into finished outputs
through a series of production processes. The Production Manager is responsible for making
sure that the raw materials are converted into finished goods effectively. The production and
planning department will set standards and targets for each section of the production process.
The production process is as follows,

• MEASUREMENT OF CLOTHES

• CUTTING OF CLOTHES

• STRITCHING OF CLOTHED

• DIVIDING INTO SIZE

• WEIGHT MACHINE

• ASSEMBLING OF CLOTHES

• CHECKING OF DAMAGES

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2.5 QUALITY CONTROL

The cloth should be well checked after clothes are made. Its may be checked in different
ways. To quickly assess an item's quality, hold the fabric up to a bright light .Do the "scrunch
test" to see if clothes stay wrinkly .And for a quick quality effects, do the "pull test ."When in
doubt shop in the men's department. Avoid exposed zippers since they can be a sign of low
quality.

2.6 ACCOUNTS DEPARTMENT

An accounting department provides accounting services and financial support to

the organization it belongs to. The department records accounts payable, and receivable,
inventory, payroll, fixed assets and all other financial elements. The department's
accountants review the records of each department to determine the company's financial
position and any changes required to run the organization cost effectively.

34
 Tally- Tally is a software which is used for day to day accounting. It is like an app
made for specific use like accounting, Payroll, manufacturing, Tax, etc.., are the basic
functions performed by Tall. It has different versions which are revised from time to
time. The company records every transaction in tally and updates in in a regular basis.
All the payables, receivables, payments and receipts are recorded in regular basis.
With the records of tally the CA checks them and prepares filing for income tax and
other legal payments.

 Accounts Payable and Receivable - The accounts payable section of an

accounting department records goods and services that it receives and the payments it
owes, such as inventory from a supplier or other expenses. The department records
each accounts payable as a liability and accounts receivable as assets. Assets such as
revenue and customers‟ obligations pay for goods and services.
 eway bill - Under GST, transporters should carry an eWay Bill when moving
goods from one place to another. e-Way Bill is mandatory for Inter-State movement of
goods of consignment value exceeding Rs.50,000/- in motorized conveyance.
Registered GST Taxpayers can register in the e-Way Bill Portal using GSTIN.
Unregistered Persons/ Transporters can enroll in the e-Way Bill System by providing
their PAN and Aadhaar. Supplier/ Recipient/ Transporter can generate the e-Way Bill.
Vehicle number can be entered/updated in PART - B of Form EWB - 01 by those who
have generated the e-Way Bill or by the Transporter. QR code is provided in the e-
Way Bill to facilitate quick verification. Certain goods have been exempted from e-
Way Bill and the list is available as Annexure to Rule 138 of CGST Rules. e-Way Bill
is not required for transport through non-motorized conveyance.
 Payroll - The payroll function of an accounting department ensures that the
organization pays its employees accurately, including bonuses, commissions and
benefits. The department monitors employees' time off, vacation and sick days. The
department reimburses employees for expenses and makes payments to vendors.
 Inventory - A company's inventory is the goods owned for the purpose of sale.
Inventory is usually sold within a year. The accounting department tries to find a
balance between high inventory levels that satisfy customers but are costly to the

35
 company and low inventory levels that satisfy the company's expenses but may
dissatisfy customers.

 Fixed Assets - In order to function effectively, a company may need machinery,

equipment, vehicles and other fixed assets it uses over several years. The accounting
department is responsible for recording fixed assets on a balance sheet with
depreciation.

The cashier who comes under the account department (at the Head Office)
carries out the function of maintaining records of the various transactions that take
place in the company. The cashier records the cash payments and cash receipts in the
cash book with reference to the voucher. These records are maintained online that
they can be viewed by the Head Office Accounts Department and the cashier
becomes accountable to them for his work. The cashier also maintains the Provident
Fund Accounts.

The employee contributes 12% towards PF and the employer also contributes
the same i.e., 12% towards the PF. The e-payment of PF is made before 15th of every
month and the payment is made in A\C No. Every new employee gives a form 2
declaration and gives his nominee name and then the UAN number is allotted to the
respective employee which enables the employee to transfer the accumulated balance
in PF A\C when he\she shifts or transfers to new concern.

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 CHAPTER-3

CORPORATE SOCIAL RESPONSIBILITY

PRIMARY FACILITY:

 Lunch are provided to the staffs and laborer’s inside the campus which costs are
not even one-third of the rates when compared to outside.
 Accommodation is provided to the workers as perquisites.

MEDICAL FACILITY

 It is a comprehensive scheme comprising medical claim, accident benefits and

compensation.

TRAINING

 Precautionary measures and proper training is given to all workers working there
once in ever year.
 Skills are trained and developed for better efficiency.

FINANCIAL FACILITY

 Giving loans for employees

 ESI (Employees State Insurance)
 PF (Provident Fund)
 Prepaid salaries are provided

37
 CHAPTER-4

SWOT ANALYSIS

STRENGTH

 Spinning Mills Cotton Mills has a management team that prides itself with vast
knowledge in the Textile Industry which make the company produce products that are
required in the market.
 Availability of skilled man power at a low cost provides an advantage for the company to
reduce its expenditure,
 Sufficient and abundant raw material help the company maintain its production flow and
hence maintain market supply and customer satisfaction.
 Investment in cutting in technology machinery ensures that the products supplied to
customers meet the desired international standards.
 The Company profits and financial investment provides a stable cash flow for expansion
and diversification in other related fields.
 The activity of the Rupee against the dollar, has positively affected the Indian cotton
industry, opening up space for companies to competitively trade in the global market.

WEAKNESS

 Investment in advanced technological means of production requires some highly trained

personnel which come at a cost for the company due to scarcity of trained machine
operators and maintainers.
 Changing global prices on cotton products might affect production costs resulting to extra
costs for the company.

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 OPPURTUNITIES

 The growing fashion industry directly affects the textile industry which is an advantage
for the cotton industry and cotton products.
 The favorable government laws on foreign direct investment are favorable for the growth
of the industry.
 The growth of the domestic and foreign market for cotton product its sufficient
opportunity for growth of expansion of the company.
 Availability of good cotton and at favourable prices around the plant reduces on cost of
raw material acquisition.
 The growing global need for cotton has led to product diversification and development
 Domestic retailing is yet to be exploited yet there is a big potential for growth in the
sector.

THREAT

 Balance between quality and pricing is a challenge but its slowly being controlled by the
growing reputation that Indian cotton is of good quality.
 Unfavorable labour laws have also proved a challenge but the company has been a big
contributor on Community Social Responsibility by building a medical clinic that
provides free healthcare for the workers and their immediate family members.
 High interest rates have made it difficult to access bank loans for expansion.

39
 CHAPTER-5

FINDINGS AND RECOMMEDATIONS

5.1 MODIFICATIONS AND RECOMMENDATIONS

 Innovation in fashion must happen frequently as SKY COTEX SPINNING MILLS

focuses only on basics.
 Their focus is mainly on bulk production, they can even focus on smaller quantity
production by taking more orders from clients.
 Trims manufacturing can be done for cost cutting.
 Can provide job offers for more employees to reduce the pressure on an individual.

40
 CHAPTER-6
CONCLUSION

The internship training which I had undergone in SKY COTEX SPINNING

MILLS was very useful. It was a golden opportunity for me to undergo training in the
highly reputed concern. The training helped me in learning about various departments,
its nature and the works carried on in the departments. The training bridges the gap
between the theoretical aspects and practical follow ups. I have understood various
terms such as gratuity, pension, ESI, PF, DA, Gross salary and Net pay. I was able to
build rapport with employees from various departments. I have learnt about the
functions of the cashier, maintenance and various other departments. I have understood
the ways to communicate with the people and to get the work on time. I understood the
importance of recollecting the theoretical learning in college and preparing myself to fit
into the job I get in. I learnt that doing our daily duties and responsibilities regularly will
make our work easy at the end and the results will be perfect. I also understood that
nothing can be excelled without practice. In general the overall functioning of the
manufacturing company is very good.

During the period of my training SKY COTEX SPINNING MILLS. I have studied
a lot of functional aspects of various departments like Production, Accounts etc. I have
also trained with the flow and delegation of authorities from the top level management to
middle and lower level of management.

The industrial training has a provided a valuable knowledge on various functions of

41
 different departments, the harmonious and the efficiency of staff and employees were
quite normal.

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

CHAPTER-6
BIBLIOGRAPHY

[Link]

[Link]

[Link]

[Link]

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