Institution Training Repor3 (1)

8/6/2019 Institution Training Repor3 (1)

1/46

INSTITUTION TRAINING REPORT

DONE AT

SELVALAKSHMI SPINNERS

AVINASHI

BY

K.SARANYA

06BBI035

IN PARTIAL FULFILMENT FOR THE COMPLETION OFBBM (IB) DEGREE

2007-2008

PSGR KRISHNAMMAL COLLEGE FOR WOMEN

(Autonomous Institution-Affiliated To Bharathiar University)

(Accredited with FIVE STAR status by NAAC)

An ISO 9001:2000 Certified Institution

Peelamedu, Coimbatore-641004


2/46

ACKNOWLEDGEMENT


3/46

ACKNOWLEDGEMENT

I take this opportunity to express my sincere gratitude to our beloved

secretary Smt.R.Nandhini for offering facilities to pursue this valuable course and

also for this institutional training.

My sincere thanks to Dr. (Mrs.) N.Yesodha Devi for giving me an

opportunity to undertake this training.

I express my sincere thanks to Mrs. S. Nirmala, Head of the Department

of business management, for permitting me to undergo this institutional training.

I am thankful to my faculty guide Mrs. Devi priya, MBA, lecturer

Department of Business Management, PSGR Krishnammal college for women,Coimbatore, for her appropriate guidance and suggestions.

I wish to record my gratitude to all other staff members of Business

Management for their Encouragement and support.

I am very thankful to Mr.Viswanathan, managing director of Selvalakshmi

Spinners. At Avinashi for permitting me to carry this institutional training in their

esteemed organization.


4/46

Contents


5/46

CONTENTS

S.NO TITLE

1. INTRODUCTION TO THE COMPANY

2. OBJECTIVE OF THE STUDY

3. ORGANIZATION CHART

4. MARKETING DEPARTMENT

5. PERSONNEL DEPARTMENT

6. PRODUCTION DEPARTMENT

7. PURCHASE DEPARTMENT

8. CONCLUSION


6/46

INTRODUCTION TO THE COMPANY


7/46

INTRODUCTION

The promoters rich and established experience in the primary cotton ginning and trading the

pioneer unit of the group . In the shortest period they have established

more spinning units. The present installed capacity of


8/46

Objective of the study


9/46

Object of the study

1. To study about different spinning machines used in the industry.

2. To gain practical knowledge about, various activities. Involved in spinning

production.

3. To study about different departments and their activities.

4. To get knowledge about the problem faced by corrective measures taken by

the company.


10/46

Organization chart

Organization chart


11/46


12/46

Marketing Department

Marketing Department


13/46

Management Responsibility:

Top manager ensure consistent and visible involvement for the

implementation of quality management system and continually improves

its effectiveness through the management.

Management Commitment:

i. Top management communication by attendingand addressing review meeting and activity

involved with functional improvement team on

customer regulations statutory and

organizational requirement.

ii. Quality product is established, documented and

maintained.

iii. Quality objectives are established in measurable

term at all three levels namely corporate level,

and operational level and

iv. Reviews are conducted in the following manner.

1. Corporate level management reviewmeeting.

2. Evidence of the above is communicated

during training, reviews and through

displays.


14/46

3. Resources are provided as an out come of

such objectives reviews in schematically.

Customer Focus:

This is carried out in a balanced way in order to satisfy the

interested parties in enhancing customer satisfaction.

All brief customer enquiries are subjected to review by managing

director before the acceptance of enquiries for deciding key

product specifications and scope of supplies.

The organization shall ensure that customer requirements.

Potential Customers:

The matrixes of customer requirements are studied

to develop potential customers in order to satisfy their exceptions.

Service:

The service and post sales service shall be provided to

customer for enhancing customer satisfaction vide customer related

process.

Environment impact:


15/46

The environments impact of the product shall be met as and

when contractually required by the customer by analyzing

environmental aspects, in respect of such process/products.

Long Term Relationship:

This is achieved through consistent quality and service.

Quality Policy:

This is communicated as through displays and through training in

order to achieve the expected results.

Steady development in technology and system enables continuous

improvements.

Objectives could be quantitatively evaluated for enhanced

customer satisfaction.

Planning:

This translates policy into measurable objectives to provide

directions in the important area through out the organization.

Quality Objectives:

The organization has identified quality objectives, in order to

meet the requirements of the customers regulatory and organizational

requirements are as follows.

1. CUSTOMER REQUIRMENTS:


16/46

INTERESTED PARTIES CUSTOMER INCLUDING

MERCHANTS, AGENTS AND END USERS VISION:

Broading customers base satisfaction.

Meeting future needs of the existing and future customers.

Customers full satisfaction.

Establishing customer driven quality policy.

Developing customer relationship with constantinteraction and

communication.

2. REGULATORY AND STATUTORY REQUIRMENTS:

INTERESTED PARTY:

Society and community around

Government bodies

Regulatory bodies

VISION:

Commercial regulatory requirements

Customer shall be satisfied subjected to satisfying all

regulatory requirements, which will improve the

nation earnings through sales tax and excise duty etc.,


17/46

Villages have benefits of employment and progressive

economic life.

Better quality life style sharing the profit with thesociety: sponsoring Eye camps, Medical camps.

SATISFYING STATUTORY REQUIRMENTS ARE:

Pollution control board act

Factory act

Personnel act

OBJECTIVE APPROACH:

Zero non conformance in maintaining regulatory and

statutory requirements.

3. ORGANIZATIONAL REQUIRMENTS:INTERESTED PARTIES

Share holders

Employees

Suppliers

VISION:

Customer oriented company


18/46

Increased involvement of employees, so that the company

shall exist for their growth and proposal

Company shall have its corporate image and product identity

increasing the net worth of the company

Supplier partnership for mutual benefits achieved through

the quality management

Management visibility.

QUALITY OBJECTIVES:-

Utilization of machine measured by time.

Utilization of materials measured by yarn realization.

Productive efficiency measured by production efficiency%

Units/1000/- spl shift [overall]

Reduction in the number of customer complaints customer

wise date.

Customer satisfaction level in terms complaints, on time

delivery.

CUSTOMER COMMUNICATION:-

i. Communication with the customer shall be attended by

managing director or by the delegated authority.

ii. Clarification in requirements, sample products, amendments,

customer complaints, and feed backs are followed by expand


19/46

and customer, related records are created in customer

communication process as given in flow diagram.

iii. The list of records generated in customer communication

process in given.

CUSTOMER COMMUNICATION PROCESS FLOW CHART

Yes

No

No

Mill Standard IOR2

Required By: MD

Stock sales

Stock sales

Contract

Is there

any

amendment

SampleApproval

Contract

Communication by

agent/customer

Communication to operational

unit

Dispatch

Production process

Indent forwarded to

operational

Shipment schedule

Is there

anyamendment

Specific order sales


20/46

Feed back from customer


21/46

Personal Department

PERSONAL DEPARTMENT

RESOURCE MANAGEMENT:-

Provides such that overall quality objectives of the organization

can be achieve and enhancing customer satisfaction.

REVISION OF RESOURCE:-

Store material in coordinating with managing director shall be

responsible for resource planning of the organization in order to ensure

that the effectiveness of quality management system is maintained and

continually improved.

RESOURCES INCULDES:-

Human resources

Technical resources and

Infrastructure resources

Prospective suppliers shall be trained for adopting and

demonstrating minimum quality management systems suitable to the

organization.


22/46

Any resource deficiencies may have adverse impact on customer

requirements are deliberated in management review meeting in order to

enhance the customer satisfaction.

Functional improvement teams are set up to study andrecommend on resources whenever applicable for improvements.

HUMAN RESOURCES:-

Human Resource provides overall improvement to the

organization through suggestions and hard works.

ASSIGNMENT OF PERSONNEL:-

i. Personnel are deployed on the basis of suitable qualification

and experience.

ii. Workers are trained on the job and continuously evaluated

for their performance.

iii. New employees shall be trained and exposed to quality

management systems by the induction training programs

before they are assigned to specific project.

iv. The exit interview shall be conducted to investigate the

reason for leaving the organization.

v. The regulatory and statutory requirements shall be adhered

for enhanced human and to protect the interest of the

interested party.

COMPETENCE, AWARENESS AND TRAINING:-


23/46

In order to provide better understanding or employees day to

day work, and to enhance their involvement, training is provided

as per training process flow as depicted under.

Training process:

i. In order to ensure effective and efficient operations, all

workers are evaluated for their competency, periodically.

Conduction of awareness class

Introduction of training

Introduction of the Mills

On the job training with trainers

Provision of all the training as per the

schedule

Evaluation if required

Continuous evaluation

Maintenance of training record

Whenever required seminars,

exhibitions, workshops,

external training shall be

provided for staffs

Exit interview


24/46

ii. Middle level management has to undergo training in quality

area development for the period of one month before they

are assigned to other areas. Periodic refresher programs for

technical personnel are also provided.

iii. Feedback of the employees during the review meeting with

the management enables an opportunity to the peoples at

operational level to be competent, motivated and thus

encouraging innovations.

iv. Training plan shall be evolved and shall be carried out on the

following in order to ensure that the personnel aware of therelevance and importance of their activities and they

contribute to the achievements of the quality objectives.

Induction training

AMS training

On-the-job training

Safety practices [Operating machines, first aid]

Material handling equipment

Electronic yarn cleared and splices [Post spinningworkers]

Development training for continual improvement on

efficiency and effectiveness of the organization.


25/46

v. Technical resources on latest technology information through

internet, magazine, seminar, work shop and test facilities shall

be provided for steady development of the organization.

vi. The records for education, skills training and experience aremaintained.

INFRASTRUCTURE:-

i. The top management continuously reviews the available facilities

to ensure that they are adequate to meet customer, regulatory and

organization requirements. Any changes in workspace, supportingutilizes, process equipments, electronic media, transportation and

communications shall be identified by the respective process

owners reports to the Top management during review meetings for

necessary actions.

ii. Any deficiency requirement capital expenditure shall be routed to

managing director for approval.

WORK ENVIRONEMNT:-

1. Safety health and environment in the working areas shall

be ensured to the employees of the organization by providing.

Humidification plant

Hot air exhaust devices

Fire extinguisher

Canteen facilities


26/46

Clean toilet facilities

Light ventilation and airflow

Rest sheds

Safe drinking water

First and kit

Health checks up in order to have positive influence on

overall performance of the organization.

2. Information technology, eternal expertise involvement,

supplier interactions through training and meeting quality cost and

benefits to decide the finance resources shall be practiced for

overall improvement.


27/46


28/46

Production Department

PRODUCTION DEPARTMENT

PRODUCT REALIZATION:-

The process planned for product realization is referred in

product.

The above process planning is developed considering the

following steps.

a) The quality objectives as defined in customer, regulatory and

organization requirements.

b) The specific product quality requirements.

c) The resources to be provided namely raw material, stored

material, human resources, measuring and testing devices,technical and machinery inputs.

d) The process of product verification and validation shall be

carried out, defining acceptance criteria.

The planning of product realization process is followed by

operational level production process as given in flow

diagram.


29/46

OPERATIONAL LEVEL PRODUCTION PROCESS

N

Receipt of I dent/information fromproduct realization planning

process

Basic meeting with functional heads

Carry out process from BIR to

windings

QAD Testing & Analysis

Passed Inform suitable

decision

Packing

Out sourcing for furtherprocessing

Yes No

Domestic Export

market

Getting blend chart from QAD

Getting blend chart from QAD

P&R maintenance of machines

electrical equipments and other

accessories

Calibration of QAD electrical &

maintenance equipments

Human resource allocation & training

infrastructure

Plant and working environment

infrastructure

Store purchase & other supportsystems

Preservation of products


30/46

CUTOMER RELATED PROCESSED:-

This ensures that the customer requirements are

managed by the process and the needs of interested parties are

understood throughout the organization.

DETERMINATION OF REQUIREMENTS RELATED TOTHE PRODUCTS:-

The organization shall determine the following factors

before commitment to supply its product to customers.

Quality requirements to be chosen from mill standards

or top decide on specific requirements.

Requirements regarding end use shall be decided on

packing, packaging and the need of sample approval

through sample development process.

Regulatory requirement in respect of quota restrictions,

commercial terms etc, and statutory requirements

regarding environmental impact of the product

whenever it is specified by the customers, taxes etc.

Additional expectations of the customers regarding

quantity, prices, quality and delivery specification.

Review of requirements related to the product:

Inspectionand grading

Packing

Dispatch Final inspection


31/46

i. The organization will review the requirements at the corporate

level by managing director with store material regarding capability

to supply as schematically shown below.

INPUT

PROCESS Output Int.Int.

Communication

ii. The review of process capability examination.

Quality based on existing stock or samples according to

endues.

Quality based on existing stock or available raw materials.

Price based on market trend, dispatch based on production

plan.

Process requirements like waxing, auto coned, auto leveling,

steam conditioned.

Packing, packaging shall be clarified by the customer.

Delivery mode shall be decided.

Commercial regulatory requirements on quote regulation and

statutory.

Review of

capabilitysatisfying

statutory and

regulatoryrequirements

Communication

to productionprocess through

production

initiation step

Stock sales or

order sales or

drop ofenquiry

Customer

requirement on

QualityQuantity

Price

Despatch

Delivery


32/46

Environmental impact shall be reviewed, whenever

applicable.

iii. The customer related process is given in flow diagram

Customer Enquire

Customer communication process

Review of

order

requirement

Stock sales

Amendments if any customer

requirements

Process at preparatory level

Testing & verification

Preservation

Despatch

Specific sales

Purchasing & verification of

raw materials

Review of

orderrequirement

Support process

Human resource & training

Maintenance

Stores purchase


33/46

Sample development

Enquiry from customerIf not matching to standards to

developing standards.

Comparison with mill standard

To provide test specification to

customer

Quotation based on markettrends

Reply to customer

Customer communication

process

To check the feasibility and

price with customer

To review raw material

availability test parameters

Receiving samples

Testing of products and matching

with end use and specification

Cost work sheet

Finalization of rates

Customer satisfaction

Management review forcontinuous improvements


34/46

The list of records pertaining too each process is listed in the developmentprocess.

In case of changes in the requirements, related to product, it shall be

amended in the respective records.

PRODUCTION AND SERVICE PROVISION:-

Top management is permitted to go beyond the product realization

process in order to enhance and ensure sustained customer satisfaction.

Accordingly production and process controlled.

CONTROL OF PRODUCTION AND SERVICE PROVISIONS:-

The operational level production process is controlled as per the flow

diagram as per the process flow diagram.

The information regarding customer requirements is provided by QAD to

operation unit level through indent.

The job instruction is listed functional wise under the control of functional

heads.

The production plan provides the process allotted for each product and it is

recorded.

The production plan provides the process shall be maintained through

preventive and routine maintenance as per maintenance schedule.

The suitable measuring and test facilities shall be provided both in

operational and QAD level calibration instruments.


35/46

The quality objective shall be measured and monitored in order to reduce

waste percentages and improve quality.

The product shall be delivered to the customer and post delivery activities

shall be followed for enhancing the customer satisfaction.


36/46

Purchase Department

PURCHASE DEPARTMENT

PUCHASING:-

This process ensures that suppliers are aligned with organization

quality policy and objectives and provides a way for supplier partnership

with the organization.

Purchase process:-The organization will evaluate each purchase process as below:-

PURCHASE

PROCESS

INPUT CRITERIA

FOR

SELECTION

OUTPUT

Raw materials Specification Despute%co-

operation

List of

approved

supplier

Store items Specification NCP, co-

operation and

delivery

List of

approved

supplier

Service Suitability Capability,

timely deliver

List approved

supplier

The training regarding purchase of above item shall be covered as

per the training plan of the job training.


37/46

The raw material shall be purchased with specified quality in

respect of length, strength and uniformity ratio and its given in the

purchase order to decide upon suitable usage according to the

product quality requirements satisfying the market needs.

RAW MATERIALS PUCHASE PROCESS:-

Incase of raw materials variation and availability, the

organization shall modify the quality plan pertaining in

process and product in order to maintain the product quality

requirements.

The store item requirements are specified for each critical

item as defined in quality records and purchase affected as

per stores. Non critical and miscellaneous items are

purchased after internal authorization.

Out sourcing: - The out sourcing services shall be carried out

for calibration of equipment transportation and woven fabricsas per the direction.

PROCESS CRITERIA FOR

EVALUATION

Calibration agency

Accuracy and precision

relationship to

national/internationalstandards. Facilities available

timely service.

Transportations

Statutory documents safe

delivery condition of the

vehicle time service


38/46

Woven fabrics

Suitability of loom for our

product [i.e. reed, pick,

width]condition of loom[maintainability of looms]

controls on looms [warp and

weft stop motion] power house

keeping

. Verification at supplier premises while availing

transportation services are not required as the verification is

carried out.

Whenever required service agencies shall be invited to

the company in order to explain the implications of bad

services of non calibrated instruments and damage while

transporting yarn.

Yarn is given as the input for fabrication using the

outside sourcing with an objective of integrating thecompany forward during the fourth coming non quota Era.

THE WOVEN FABRICS ARE OUT SOURCED AS PER THE

PROCESS FLOW SHOWN BELOW:

YARN

PERN WINDINGSIZING


39/46

In this out sourced process controls are three locations.

Sizing shed

Loom shed

Logistics of yarn, beam and fabric

The controls carried out for the following:

Identification of mill yarn, beam and fabric

in each stage. Verification for quality, quantity at sizing

shed and loom shed.

QUALITY IS VERIFIED AGAINST ATTRIBUTE

DEFECTS SUCH AS:

S.NO NAME OF THE DEFECTS

WEAVING


40/46

1 Colour

2 Knots

3 Slub

4 Slubey weft

5 Soft yarn

6 Broken ends

7 Broken pattern

8 Double ends

9 Float

10 Hole cut, tear

11 Local distortions

12 Missing ends

13 Oil or strains yarns

14 Oily or soiled ends

15 Oily weft

16 Read mark

17 Selvedge defects


41/46

18 Smashed

19 Loose threads

20 Weft bar

21 Weft crack

22 Starting mark

23 Width shortage

24 Pick short

25 Wrong drawing

26 Wrong decision

27 Weight mark

28 Pencil mark

29 Temper mark

30 Emery roller mark

And variables defects such as:-

1. READ

2. PICK

3. WIDTH


42/46

Preservation and protection of yarn, beam and fabrics from fire

hazards, wet areas and contamination.

Implementing house keeping principles lucidity displaying the

spirit of house keeping.

In order to ensure consistent performance the outsourcing

suppliers of women fabric evaluated for the following in the

supply chain.

The process of purchasing their store materials at the operational

unit level is depicted in stores purchase process flow diagram.

The suppliers evaluation on the capabilities to supply is carried

out as schematically.

The purchase information with regards to quality, by providing,

specimen, previous supply reference shall be incorporated while

preparing purchase, order by senior assistant and other relevant

informations such as delivery, quantity and commercial terms willbe furnished. The purchase order shall be released by the joint

managing director.

The non -critical miscellaneous item shall be purchased from any

supplier supported with bills, after authorization by joint director.

Re evaluations

on previous

supply results in

respects of

Quality, delivery

and co-operation

At operational

level by

manager, as

authorized bydirector

providing ratings

or supply

According to

85% and more

ratings suppliers

listed.


43/46

The purchased store items shall be verified against commercial

documents and purchase order by the respective for every critical

item and by senior assistant for non-critical items.

The store suppliers are involved in the organization for mutual

trust and benefits as under.

Communicating to them on quality and safety issued of the

supplier products evaluating with competitors.

Requesting suppliers to provide in plant development training on

the usage of products supplied by them for respective functionalworkers in the organization.

This way supplier partnership is established in the quality

management system.


44/46


45/46

Conclusion

CONCLUSION

The Industrial training program, which I undertake at

Selvalakshmi Spinners, has been very much useful to me. I was indented

to all the activities took place in the industry. The information gathered

by me in this institutional training rendered a huge amount of experience

that supply me for studies and could improve my knowledge.

From this institutional training, I am able to understand the

motives of the industry and the way by which they have been following

to achieve their motives.

The industry training has aided getting a very good idea about theproduction which is more useful then theoretical study.

The above study reveals that by careful organizing and team

management will pay way for the growth and good prospectus for

achieving, profits, which is ultimately the main aim of every business.

The study has enlightened me in the area like the various functions

of the organization, purchases, marketing, system control and planning,

organization, staffing, and controlling and resource management.


46/46

Thus I conclude saying that the field work I undertook has given

me through knowledge in all the aspects.

Institution Training Repor3 (1)

Documents

Transcript of Institution Training Repor3 (1)