O

Ravi Shekhar

SEM-V, NIFT DELHI

Auro Spinning Mills – Hall 5

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TABLE OF CONTENTS

ACKNOWLEDGEMENT 1 2

VARDHMAN GROUP 2 3-6

INTROUCTION 2.1 3

MANUFACTURING 2.2 3

PORTFOLIO 2.3 5

ADMINISTRATION 2.4 5

QUALITY POLOCY 2.5 6

PHILOSOPHY 2.6 6

AURO SPINNING MILLS 3 7-27

PRODUCTION DETAILS 3.1 7-8

AURO LAYOUT 3.2 9

RAW MATERIAL STORAGE AND FIBER INSPECTION 3.3 10

PROCESS FLOW 3.4 11

BLOWROOM 3.5 12-15

CARDING 3.6 16-17

DRAWING 3.7 18

LAP FORMER 3.8 19

COMBING 3.9 20-21

FINISHER DRAW FRAME 3.10 22

DRAW FRAME 3.11 23

SPEED FRAME 3.12 24

RING FRAME 3.13 25

WINDING 3.14 26

PACKING 3.15 27

SPIN CALCULATION & PLANNING PRODUCTION 4 28-46

GOAL OF THE PROJECT 4.1 28

THE PROPOSAL 4.2 29

AN INTRODUCTION TO NEW SYSTEM 4.3 30

ASSESMENT OF CURRENT SYSTEM 4.4 31

SILENT FEATURES OF NEW SYSTEM 4.5 33

TECHNICAL REQUIREMENT FOR NEW SYSTEM 4.6 34

DEVELOPERS REQUIREMENT 4.7 35

DATA FLOW DIAGRAM 4.8 36

UNIT CONVERSION AND SPIN CALCULATION 4.9 37

MAINTENANCE : UPDATION & SUPPORT 4.10 44

SNAP SHOTS 4.11 45

BIBLIOGRAPHY 5 47

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ACKNOWLEDGEMENT |

 

This   Internship  Proved  to  bridge  the  gap  between  the  theoretical  and  Practical  

Aspects  of  textile  Field.  It  was  a  great  pleasure  to  be  part  of  Vardhman  Group.    

All  Thanks  to  my  institute  NIFT,  New  Delhi  for  providing  me  the  opportunity  for  

getting  the  practical  knowledge  at  such  an  eminent  company.    

   I  am  also  greatly  thankful  to  my  subject  faculty  Dr.  Senthil  Venkat  for  the  full  

support   and   step-­‐by-­‐step   assistance.   I   am   also   Thankful   to   my   Internship  

Mentors  Dr.  Noopur  Anand  and  Ms.  Suruchi  Mittal.  

I   am   very   thankful   to   the   whole   Vardhman   Group   for   providing   me   the   best  

possible   facilities   and   good   environment   during   the   period  of  my   internship.   I  

acknowledge   deep   gratitude   towards   each   and   every   employee   of   the   Auro  

Spinning  Mills,  Baddi  for  providing  me  with  their  valuable  time.  

I  would  also   like   to  express  my  gratitude   towards  my  mentor  Ms   Parul   (HRD)  

and  Project   Guide  Mr.   Punit   Singhal   (R&D)   for   giving  me   chance   to  work   on  

such  a  nice  project.  I  pay  my  thanks  to  Mr.  Vipin  Sachan,  Mr.  Sunil  Mishra  and  

Mr   Harpeet   Rana   (Shift   Officer,   Unit   5)   who   gave   his   valuable   time   and  

attention  during  my   training  and  completion  of  project   report..   Instructions  of  

each  person  I  meet  in  Auro  were  very  beneficial  for  the  successful  completion  of  

my  project  report.  

I   pay  my   special   thanks   to  all   the  other  HODs  also   for   their   valuable   time,   co-­‐

operation,,   guidance   and   providing   useful   data,   namely  Mr   Ravindra   Yadav  

(R&D),  Mr  Devendra  Vasist(R&D)      and  Un-­‐doubly  Mr  Ravi  Ranjan  (TPM)  for  his  

all  source  of  inspiration  all  along.  

 

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VARDHMAN  GROUP  2|TWO  

 Vardhman  is  a  leading  conglomerate  with  interests  in  textiles  and  steel  having  a  

turnover  of  Rs.2100  crores.  The  Vardhman  group  comprises  six  companies  and  

twenty  production  units  located  in  Punjab,  Himachal  Pradesh  and  Madhya  

Pradesh.  A  growth  rate  of  almost  15%  per  year  in  turn  over  the  last  five  years  

has  been  reflected  in  the  financial  results  of  the  group.    

MANUFACTURING  2.2|TWO  

 Vardhman   group   consists   of   integrated   facilities   of   spinning,   weaving   and  

finishing.  By  and  large  it  has  a  strong  focus  on  textiles,  which  remains  the  largest  

industry  in  our  country.  

•  Over  8,  00,000  spindles  

•  65  tons  per  day  yarn  and  fiber  dyeing  

•  900  shuttle-­‐less  looms  

•  90  million  meters  per  annum  processed  fabric  

•  33  tons  per  day  sewing  thread  

•  18000  metric  tons  per  annum  acrylic  fiber  

•  100,000  tons  per  annum  special  and  alloy  steel  

Vardhman  started   its  operation   in  1965  from  Ludhiana  with  a  modest  capacity  

of  14000  spindles.  Today  5,  00,000  spindles  which  is  largest  any  single  group  has  

in   India.   Besides   it   has   weaving   capacity   of   264   looms   and   fabric   finishing  

capacity  of  95,000  meter  per  day.   In  addition   it  has  mercerizing  and  dyeing  of  

yarn  and  fiber  and  an  acrylic  production  unit  at  Gujarat.  

Spin Weave Process

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MANUFACTURING UNITS 2.2.2|TWO

Vardhman   group   consists   of   integrated   facilities   of   spinning,   weaving   and  

finishing.  By  and  large  it  has  a  strong  focus  on  textiles,  which  remains  the  largest  

industry  in  our  country.  

• Vardhman Spinning and General Mills Ltd.

• Vardhman Spinning and General Mills Ltd. Ludhiana

• Auro Spinning Mills Baddi, H.P.

• Auro Dyeing Baddi, H.P.

• Auro Weaving Mills Baddi, H.P.

• Auro Textiles Baddi, H.P.

• V.S.G.M. 100% E.O.U. Baddi, H.P.

• V.S.G.M. Unit 2 Ludhiana

• V.S.G.M. Unit 3 Ludhiana

• Mahavir Spinning Mills Ltd.

• Mahavir Spinning Mills Ltd. Hoshiarpur

• Arihant Spinning Mills Malarkotla

• Anant Spinning Mills

• Vardhman Special Steel Lidhiana, Punjab

• M.S.M.L. Sewing Threads Unit 2 Ludhiana, Punjab

• Arist spinning Mills Baddi, H.P.

• Arist Spinning Mills 100% E.O.U. Baddi, H.P.

• Vardhman Polytex ltd.

• Vardhman Ploytex ltd. Bhatinda, Punjab

• Anshupati Textiles Ludhiana, Punjab

• V.M.T. Spinning Co. Ltd. Baddi, H.P.

• Vardhman Acrylic Ltd. Bharuch, Gujrat

• Vardhman Threads Ltd. Baddi, H.P.

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PORTFOLIO 2.3|TWO

ADMINISTRATTION 2.4|TWO

Corporate  office  located  in  Chandigarh  road  in  Ludhiana  adjacent  to  Vardhman  

Spinning  and  General  Mills  Ltd.(Ludhiana).  It  came  into  being  in  1995.  

Vardhman  Group  has  administrative  and  marketing  branches  all  over  India  and  

in  more  than  20  countries  for  its  various  businesses.  The  group  is  well  diversified  

in   making   sewing   threads,   fabrics,   hand   knitting   yarns,   cotton   yarns,   acrylic  

yarns   etc.  with   a   capacity   of   over   5,00,000   spindles   and   264   looms   producing  

yarns  and  fabrics.  

Shree   S.P.   Oswal,   a   gold   medalist   in   M.Com.   heads   the   group   who   is   the  

chairman  and  managing  director  of  all  group  companies.    

Fiber

8%

Power

Plant

2%

Steel

10% ST

11%

Fabric

22%

Yarn

47%

Business Wise TurnOver for

Financial Year 2008-2009

Fiber PowerPlant Steel

ST Fabric Yarn

Actual 2008-09 Group Total

( � crores)

USD Million % Share

Yarn 1513 329 47%

Fabric 689 150 22%

Sewing Thread 337 73 11%

Steel 327 71 10%

Power plant 66 14 2%

Fibre 254 55 8%

Total 3186 693 100%

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QUALITY POLICY 2.5|TWO

Quality   should   be   built   into   company’s   products   to   not   only   meet   customer  

requirements   continuously   but   also   exceed   them.   The   company   shall   achieve  

this   through   an   interface   with   the   market   place,   access   to   state   of   the   art  

technology,   R&D   process   development   and   adoption   of   innovative  

manufacturing  and  marketing  strategies.  

The   quality   policy   shall   be   implemented   through   a   network   of   systems   and  

procedures  understood  and  followed  throughout  the  company.  

The  quality  policy  shall  be  integrated  with  the  company’s  main  objectives:  

1.  To  remain  market  leader  in  the  quality.  

2.  Increase  market  share  with  focus  on  niche  segments.  

3.  Improved  productivity.  

4.  Cost  reduction.  

5.  Reduction  in  percentage  of  seconds.  

6.  The  management  shall  be  committed  to  provide  capital  and  human  resources  

to  achieve  the  above  objectives.  A  companywide  quality  culture  shall  be  created  

through  training  and  motivation  of  people  at  all  levels  of  organization.  

PHILOSOPHY 2.6|TWO

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AURO SPINNING MILLS (77904 SPINDLES) 3|THREE

Auro Spinning Mills Baddi (Himachal Pradesh) 77904

Auro   weaving   mills,   a   weaving   subsidiary   of   Vardhman   Spinning   and   General  

Mills  Limited,  has  now  emerged  as  one  of  the  premium  companies  in  India.  

PRODUCTION DETAILS 3.1|THREE

Production Halls Production Units 5

UNIT 1 (HALL1) 3.1.1|THREE

Manufacturing Activity Greige Cotton ( both cared & combed) and core

spun with lycra.

Unit Capacity • 24,422 spindles

• Production of yarn per day: 16,000 kg

Product Range 10s-60s

UNIT 2 (HALL 2) 3.1.2|THREE

Manufacturing Activity Sliver preparatory and sample line

Unit Capacity • 1382 spindles

• Production of sliver per day: 9,000 kg

Product Range Lycra, compact, compact+lycra, slub+lycra,

slub, Blends

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UNIT 3 (HALL 3) 3.1.3|THREE

Manufacturing Activity Cotton and lycra (bulk orders)

Unit Capacity 38592 spindles

Product Range Lycra, slub, fancy yarns

UNIT 4 (HALL 4) 3.1.4|THREE

Manufacturing Activity Open- end yarn

Unit Capacity • 1248 rotors

• Production of yarn per day: 12,000 kg

Product Range 6s-20s

UNIT 5 (HALL 5) 3.1.5|THREE

Manufacturing Activity Compact ( Elite) spun yarn

Unit Capacity 14256 spindles

Production of yarn per day: 4000 kg

Product Range 40s-200s

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AURO LAYOUT 3.2|THREE