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The
Summer Internship Project Report
On
Organizational Overview
At
BIRLA VXL LIMITED
FABRICfor that GREAT SUIT
Submitted by
KHANDHAR NILESH
MBA Sem II
Academic Year : 2010-2012
T.N. RAO COLLEGE RAJKOT
Guided by,
SHOIAB A. LOHANI
Submitted to,
GANESHPRASAD SINGH SIR
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EXECUTIVE SUMMARY
The textile sector is one of the fastest growing sectors in the economy. There are many
players in this sector but DIGJAM is a step ahead of them all. DIGJAM is committed to
satisfy customers by providing quality products and services, which give highest value
for money. They believe that their employees are their most important assets through
which they can reach the top in each field they venture into.
ITS WHO YOU AREthey commit themselves to continuous growth so as to fulfill
the aspirations of the customers, employees and shareholders.
The whole project is based on understanding the two Ps of marketing i.e., Product and
Promotion.
I am really very thankful to the management at DIGJAM for giving me to an opportunity
to undertake a project work in their organization. I hope that the work done by me is
satisfactory.
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CORPORATE
PORTFOLIO
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CORPORATE PROFILE
REGISTERED OFFICE:
DIGJAM Limited,
Aerodrome Road,
Jamnagar 361 006
Gujarat.
CORPORATE OFFICE:
DIGJAM imited
801, Bhikaji Cama Bhawan 11,
Bhikaji Cama Place,
New Delhi 110 066,
India
UK Representative Office
DIGJAM Limited
18 King shill Avenue Harrow,
Middlesex HA3 8JP,
United Kingdom
Tel: .(44) 208 907 8687
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Fax: (44) 208 909 2527
E-mail :[email protected]
OTHER OFFICES:
Delhi
Mr. Amit Gupta
DIGJAM Limited, 501, 2nd Floor, Krishna Gali,Katra Neel, Chandni Chowk
New Delhi 110006
Punjab
Mr. Balbir Sharma / Mr. Alok Pachauri
DIGJAM Limited, 3 Kairon Market, 2nd Floor,Hall Bazar
Amritsar 143006
West Bengal
Mr. Ashok Bodhania / Mr. N K Sharma
DIGJAM Limited, 9/1 R N Mukherjee Road
Kolkata 700001
PRINCIPAL OPERATING DIVISION:
Aerodrome Road, DIGJAM LIMITED,
Jamnagar 361 006
Gujarat
REGISTERED AND SHARE TRANSFER AGENTS:
MCS Limited,
77/2A, Hazra Road, 3rd & 5th Floor, Kolkata 700 029
mailto:[email protected]:[email protected]:[email protected]:[email protected] -
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Tel (033) 2476 7350 54, 2454 1892 93
Fax: (033) 2454 1961, 2474 7624
e-mail: mailto:[email protected]
AUDITORS:
Deloitte Haskins & Sells
BANKERS:
o UCO Banko Bank of India
o Bank of Baroda
o PNB
o Punjab & Sind Bank
o SBI
o SBS
o
Standard Chartered Banko UBI
BOARD OF DIRECTORS:
o S. K. Birla Chairman
o Siddharth Birla Vice Chairman
o
N. Lalbhaio R.K. Chaudhary
o Dr. G. Goswami
o Gauri Kumar
o G. Momen
o C. Mukherji
o P. K. Pujari
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EXECUTIVES:o C.L Rathi M. D
o M. R. Surekha Co. Secretary and Executive V. P (Legal)
o R. K. Kedia President
o Virendra Gupta V.P. (Exports)
o Ravinder Sharma V.P. (Sales and Marketing)
o P.K. Das V.P. (Exports) and Business Head
STOCK EXCHANGE LISTING:
o More than 93000 shareholders listed in
o BSE
o NSE
o Kolkata Stock Exchange
o Delhi Stock Exchange
o
Saurashtra Kutch Stock Exchange
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MISSION & VISION OF COMPANY
MISSION
To be an enterprise acclaimed for its products & services among peers and customeralike, by having responsible workforce & through best available technology
VISION
To be the clear favorite & premium contender in our principal market.
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INDUSTRY OVERVIEW
Textile Industry in India is the second largest employment generator after agriculture. It holdssignificant status in India as it provides one of the most fundamental necessities of the people.Textile industry was one of the earliest industries to come into existence in India. In fact Indian
textile industry is the second largest in the world, second only to China.
Textile Industry is unique in the terms that it is an independent industry, from the basic requirementof raw materials to the final products, with huge value-addition at every stage of processing. Textileindustry in India has vast potential for creation of employment opportunities in the agricultural,industrial, organised and decentralized sectors & rural and urban areas, particularly for women.
Till the year 1985, development of textile sector in India took place in terms of general policies. In1985, for the first time the importance of textile sector was recognized and a separate policystatement was announced with regard to development of textile sector. .
India Textile Industry is one of the leading textile industries in the world. Though was predominantlyunorganized industry even a few years back, but the scenario started changing after the economicliberalization of Indian economy in 1991. The opening up of economy gave the much-needed thrustto the Indian textile industry, which has now successfully become one of the largest in the world.India textile industry largely depends upon the textile manufacturing and export. It also plays a majorrole in the economy of the country. India earns about 27% of its total foreign exchange throughtextile exports. Further, the textile industry of India also contributes nearly 14% of the total industrialproduction of the country. It also contributes around 3% to the GDP of the country. India textileindustry is also the largest in the country in terms of employment generation. It not only generates
jobs in its own industry, but also opens up scopes for the other ancillary sectors. India textile industry
currently generates employment to more than 35 million people. It is also estimated that, the industrywill generate 12 million new jobs by the year 2010.
In the year 2000, National Textile Policy was announced. Its main objective was:
To provide cloth of acceptable quality at reasonable prices for the vast majority of thepopulation of the country,
To increasingly contribute to the provision of sustainable employment and the economicgrowth of the nation,
To compete with confidence for an increasing share of the global market.
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Various CategoriesIndian textile industry can be divided into several segments, some of which can be listed as below:
Cotton Textiles Silk Textiles Woolen Textiles Readymade Garments Hand-crafted Textiles Jute and Coir
The IndustryIndia textile industry is one of the leading in the world. Currently it is estimated to be around US$ 52billion and is also projected to be around US$ 115 billion by the year 2012. The current domesticmarket of textile in India is expected to be increased to US$ 60 billion by 2012 from the current US$
34.6 billion. The textile export of the country was around US$ 19.14 billion in 2006-07, which saw astiff rise to reach US$ 22.13 in 2007-08. The share of exports is also expected to increase from 4% to7% within 2012. Following are area, production and productivity of cotton in India during the last sixdecades
Strengths
Vast textile production capacity Large pool of skilled and cheap work force Entrepreneurial skills Efficient multi-fiber raw material manufacturing capacity Large domestic market Enormous export potential Very low import content Flexible textile manufacturing systems
Weaknesses
Increased global competition in the post 2005 trade regime under WTO Imports of cheap textiles from other Asian neighbors Use of outdated manufacturing technology Poor supply chain management Huge unorganized and decentralized sector High production cost with respect to other Asian competitors
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Current Facts on India Textile Industry
India retained its position as worlds second highest cotton producer.
Acreage under cotton reduced about 1% during 2008-09. The productivity of cotton which was growing up over the years has decreased in 2008-09. Substantial increase of Minimum Support Prices (MSPs). Cotton exports couldnt pick up owing to disparity in domestic and international cotton
prices. Imports of cotton were limited to shortage in supply of Extra Long staple cottons.
Textiles Major Companies
AlokTextile
Indianra on
GTNtextile
Century
Gokuldas
Morarjee
SardaTextile
Digjam
Verdhman
Raymond
Arvindmill
Major
la ers
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COMPANY HISTORY / INTRODUCTION
DIGJAM Limited, an S K Birla Group Company, began its activities nearly 60 years back inJamnagar, Gujarat. Since then, it has been catering to the ever-growing demands of the Clothing andFashion industry, in the domestic as well as the international markets.
DIGJAM Limited is a leading textile company in India, manufacturer of fabrics for suiting andcasual wear. In recent years, the company restructured its business portfolios to focus as a textilecompany manufacturing and marketing fabrics and ready-to-wear clothing under its own brands.
A complete vertically integrated plant, DIGJAM has ultra modern production facilities to convertwool tops to finished fabrics through different processes of Dyeing, Spinning, Weaving and
Finishing using state-of-the-art machinery imported from France, Germany, Switzerland and Italy.Stringent quality checks at every stage and process enabled DIGJAM to bag the prestigious ISO9001 certification. Keeping pace with the complex requirements of the industry, DIGJAMexpanded its production capacity to over 5 million meters, of which 35%-40% (approximately) isexported to major countries across the globe.
Andersen Consulting, a leading management and corporate advisors agency, undertook a majorreview of the operational parameters of our textile company. Following a thorough review of theoperating and marketing practices, recommendations were made which now form the basis of ourstrategic marketing and manufacturing thrusts spanning the coming 3-4 years. The company has alsoinitiated steps to strengthen its organization and induct the youth and skills necessary to attain results
from this strategic shift-cum-consolidation exercise.
While the company lays uniform stress on all fundamental aspects such as quality, designs and cost-friendliness for products under all its brands, DIGJAM is undoubtedly its premium fabrics brand.DIGJAM has a high-end fabric brand presence in the domestic market, reputed for its finish andquality. The company manufactures over 3000 design-shade combinations each year in Light Wool,Polyester Wool and Woolen fabrics for the DIGJAM brand alone. Constant research on designsensures creation of innovative future trends. In the new millennium, DIGJAM introduced super-premium fabrics designed by European experts (with whom we work regularly and extensively)comprising fine wool yarn of Super 150s and Super 120s and occasionally blended with exotic fiberslike Silk or Cashmere.
Dressing in India has come of age - rising affluence levels, increased media exposure of internationalfashions and a growing tendency towards self-indulgence have all contributed to it. The all roundimpact is visible with the influx of international, and domestic products and brands in both, formaland casual wear. Indian customer has choice today, but one where we are determined to make andsustain our mark.
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The DIGJAM brand will increasingly reflect both tradition and modernity in its positioning, productrange and marketing approach. We intend to position the brand as the clear favorite for a wider, butdemanding clientele with special emphasis on becoming the preferred premium choice for theyouthful consumer. This segment offers a high potential in terms of market size and also presents atougher challenge to us in terms of providing satisfaction. DIGJAM'S superior product quality is at
par with global standards and many of the world's best readymade brands use fabrics produced by us.A major proportion of our output is exported to USA, Europe, Middle East and Far East. This bodeswell for our future as our preeminent position as one of the largest manufacturer of textiles fromIndia.
Our marketing thrust will over time impact all facets of the brand's interface with consumers,including new product introductions, consumer promotions and the rich retail experience. It must benoted that the DIGJAM brand has been ranked at no. 4 among the top Apparel brands of our country,in a study conducted by the prestigious Economic Times newspaper of the Times of India group.Apparel category comprised of all the top Fabric brands as well as the Readymade Garment brandsavailable in the country. This particular study at the consumer level at a national level was conducted
to find out India's Most Trusted Brands.'
DIGJAM products and their ranges are available at its exclusive showrooms and over 3000 otherretail outlets across the country.
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MANAGEMENT ORGANIZATION STRUCTURE
Chart 1: Organization Chart (1)
Board of Directors
Managing Directors
President
Vice President
Export & Head
universal
Vice President
Technical
Vice President
Sales &
marketing
Vice President
Legal
GM
Personnel
GM
Sales & Mktg.
GM
Finance
GM Corp.
Finance
Company
Secretary
Area
Manager
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DOMESTIC SALESVP (S&M)
(Shri Ravinder Sharma)
Chart 2: Organization Chart (2)
East West South North
SR.Manager
(Shri Rajesh Sharma)
DY.GM
(Shri Sharad Goel)
GM(Shri Amit Gupta)
SR.MANAGER
DY. MANAGER / ASST. MANAGER
SALES OFFICERS
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SELLING REPRESENTATIVES / AGENTS
DIGJAM
SRs SALES TEAM
WHOLESALERS/ EXCLUSIVE MULTIDISTRIBUTORS SHOWROOMS BRAND
OUTLETS
TAG DEALERS
CONSUMER
Chart 3: Organization Chart (3)
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General information
1 Name of the firm DIGJAM LTD.
2 Brand name DIGJAM3 Years of establishment4 Form of organization Public Ltd. Co.5 Location of Unit DIGJAM LTD.
Aerodrome road, Jamnagar. 361006
(Gujarat-India)
6 Tel. No. +91(0288)2712972/73
7 Fax No. +91(0288)27129918 E-mail [email protected] Web site www.digjam.co.in
10 Corporate Office 801, Bhikhaji Kama Bhavan, New Delhi-110066
11 Promoter S.K. Birla
12 Certified ISO 900113 Board O Directors S.K. Birla (Chairman)
Siddharth Birla (Vice Chairman)
A.N. Lalbhai
Arvind Agrawal
R.K. Chaudhary
Dr. G. Goswami
N.L.Hamirwasia C.L. Rathi(MD)
Rajiv Sharma (Executive Director& Chief Operating Officer)
14 Auditor Kimji Kunvarji & Co., (C.A.) Mumbai.15 Bankers UCO Bank
Bank Of India Bank Of America
Bank Of Baroda Punjab National Bank
State Bank Of Saurashtra Standard Chartered Bank
mailto:[email protected]://www.digjam.co.in/http://www.digjam.co.in/mailto:[email protected] -
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Union Bank Of India
State Bank Of India16 Clients Aditya Birla Nuvo
Airport Authority Of India
Alcock Ashdown (Gujarat) Ltd. Arvind Brands
Arvind Clothing Ltd. Assam Rifles
Banaras Hindu University Bharat Heavy Electronic
Ltd.(BHEL)
Bharat Petroleum Corp. Ltd.
Birla Institute Of Technology
Bombay Hospital
Castrol (India) Ltd.
Gujarat Alkalies & ChemicalsLtd.
Gujarat Industrial Power Co.Ltd.
Gujarat Narmada ValleyFertilizer Corp.
Gujarat State Fertilizer Corp. Hindustan Motors Ltd.
Hindustan Petroleum Corp. Ltd.
ICICI Ltd.
INDAL
Indian Air Force
Indian Aluminum Co. Ltd.
Indian Farmers Fertilizers Co-Op Ltd.
Indian Oil Corporation (GujaratRefinery) ITC Ltd.
ICFAI Business School,Ahmadabad
Mohan Clothing Company.
M.S. Patel Institute Ofmanagement, M.S. University
Mysore Cement ltd.
NCL Naval H Q.
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Ordinance Clothing Co.
Reserve Bank Of India SAIL
Suarashtra Chemicals
Shoppers Stop Ltd. Sports & Leisure Apparels Ltd.
Taj Trade Transport Co. Ltd.
Tamil Nadu Police
Tata Industries Ltd.
Tata Timken Ltd.
Tehri Hydro Development Corp.Ltd.
17 Company Logo ITs who you are18 Production Capacity Year:- 73,00,000 Meters
Day:- 20,000 Meters19 Export 50%
20 Import 50%21 Exported Country U.S.A., Canada. U. K., Europe, Middle
East & Far East , Japan , Australia etc.
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DIGJAM ACHIEVERS UNLIMITED (DIACHS) CLUB
A unique and one of kind exclusive club created for the first time in the industry. Based on
certain parameters and criteria, top Wholesalers, Retailers and Digjam Retail Showrooms
were selected for the DIACHS Club.
Objective is to work together for mutual benefit and increase our business. To reward the
good and consistent performers and to enter into a committed, long-term relationship with
the Dealers. Membership valid for 1 year. The members have the following benefits:
Special incentive on turnover on achievement of a minimum turnover target (based
on certain parameters).
Special Qualities / Design Selection: Special qualities to be developed for Achievers
Unlimited members. Participation and involvement of club members for range
development.
Special samples of selected / fast moving qualities to be provided to club members.
Achievers Unlimited Members Meet - To participate in DIACHS Meet organized
once in a year. In such functions, the top performing members to be awarded and
honored by top management.
Special Service: To give priority to them in order procurement and execution. Suitlengths to be dispatched to club members through courier on paid basis.
Special Certificate recognizing members as part of the Digjam Achievers Unlimited
family.
The formation of this unique club was made know to the achievers at Dealers Meet
organized at The Intercontinental, Goa in September, 2004.
http://www.digjam.co.in/Web/digjam_achievers.aspxhttp://www.digjam.co.in/Web/digjam_achievers.aspxhttp://www.digjam.co.in/Web/digjam_achievers.aspx -
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AWARDS & RECOGNITIONS
Table 1
Awards & Certification Year
1) Confidence in Textiles 2007
2) ISO 9001:2000 2007
3) Lycra Assured 2005
4) Export House Certificate 2004
( Source:www.digjamsuiting.com)
Credentials
Awards:
Highlights - Why Digjam is Ahead :
1. Using the best technology and machines available, Digjam has achieved the ISO
9001 international quality Certification.
2. Impressive capability: The present production capacity of over 20,000 meters of
woolens per day is one of the highest in the industry.
3. Exporting nearly 35% if its total production. Digjam textiles are now in use in the
U.S., Canada, U. K., Europe, Middle East Far East, Japan & Australia.
4. For four consecutive years, DIGJAM Limited has received the highest ExporterAward, in the woolen worsted category, from the export Promotion Council, a Govt.
of India Undertaking.
5. Digjam is a Unit of the trusted Birla Group of Industries with a world-wide presence
and strong reputation.
6. The first and only worsted mill in India to be awarded the status of "ACCREDITED
MILL" from the internationally renowned DuPont.
http://www.digjamsuiting.com/http://www.digjamsuiting.com/http://www.digjamsuiting.com/http://www.digjamsuiting.com/ -
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7. Woolmark & Wool blend mark license from International Wool Secretariat.
Digjam has been awarded the status of "ACCREDITED MILL" from the internationally
renowned DuPont and is now a part of the elite LYCRA ASSURED Network, which is the
world's leading supply chain for innovative, quality stretch fabrics.
In this difficult business environment, alliances are becoming more important than ever and
the ability to differentiate one's company is even more crucial. These two business needs
are the drivers behind our decision to be part of the exclusive LYCRA ASSURED
Network.
The goal is to create value in the LYCRA ASSURED Network as a whole, thus making it
the automatic first stop for the world's leading buyers looking for premium stretch solutions
and the latest fiber and fabric innovations and new concepts. The expanded support and
services planned by DuPont as part of the value delivered by membership in the Network
are mentioned below:
Early access to new DuPont technologies and exciting innovations not only for Lycra, but
also for other important products like Teflon, Tactel, Coolmax, Cordura, Supplex,
Thermolite, and technical support.
New revenue growth opportunities.
Significant cost and competitive advantages.
Constant promotion of LYCRA ASSURED Network benefits and the products of its
partners to key buyers.
Keeps us at the forefront of stretch innovations.
New global sourcing options - from fiber through garment.
ATS fabric library.
Exclusive or priority access to market research. Participation in exclusive retail and
consumer promotions.
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FLOW CHART OF DIGJAM LIMITED
Sales &marketing
department production
department
Prod. Planning& control
department
Exportdepartment
Financedepartment
Humanresourcedepartment
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INTRODUCTION
Since production is the process of converting inputs into finished goods and services, it must bemanaged. It deals with proper use of manpower and machinery for transforming raw material intofinished product.
Production management deals with decision making related to the production process, so as to the
resulting goods and services produced according to the specification, in the amounts and by thescheduled demanded and at minimum cost.
Production is the process to create or manufacture the goods and services. It is the main process by
which an organization sale their product after the production of goods and services.
Production is a function of planning, organizing and controlling through which a unit convert the rawmaterials into finished goods. It includes the following:
Raw materialsProcurement and storage of raw materialsManufactured products
DIGJAM Ltd. has a drastic manufacturing unit in Jamnagar with a working environment. It ismainly producing the fabric clothes through various process of production with starts from greycombing and ends with finished product that is called fabric.
Plant location
Section of plant is very sturdy job for any production unit because ultimately every organizationwants to reduce their cost of production and also wants to get every facility near to the place as wellas a good layout where it will produce its products.
DIGJAM Ltd. Is located as a coastal region of Jamnagar at Gujarat because this land was given byH.H.Jamsaheb and which is helpful to import raw material like wool and export the finished productand also helpful for local transportation because of the remote town. Near to the plant all the facilityare available like electricity, school, bank, stores, hospital, market, transportation, economical
atmosphere, labors, machineries and securities.
The total weaving capacity of the plant is 7 million meters p.a. The plant spread over 47 acres,employees 515 executives and a dedicated force of 1600 workers.
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Raw materials and products
Raw material is the basic need for a manufacturing unit through which the production process andoperation cycle run.
In DIGJAM Ltd. The raw materials are two types :-
MERINO wool (natural fiber) Polyester
1. MERINO woolMERINO wool is purchased mainly from Australia, South Africa and New Zealand.
Wool is natural fiber which is used to make the fabrics in DIGJAM. This wool is testedand certified for its quality by IWTO (international wool testing organization). Theconsignment from Australia must have the Australian wool testing certificate (AWTCrecognized).
2. Polyester:-Polyester is manmade fiber comes in DIGJAM from reliance and IOCL pondichery.Some variety of polyester is imported from Germany. Types of polyester used inDIGJAM are
a) Semi dullb) Sparkling whitec) Normal whited) Black
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PRODUCTION PROCESS
DIGJAM Ltd. Completely vertically integrated plant located in Jamnagar has ultra modernproduction facilities to convert wool top to finished fabrics through different process of greycombing, dyeing, spinning, weaving, folding and finishing using state of the art machinery imported
from France, Germany, Italy, Switzerland, Belgium and south Korea. The company manufacturesmore than 1000 quantities in over 3000 design shades combination each year in light wool andwoolen fabrics for the DIGJAM brand alone and also free with practically no pollution.
PRODUCTION PPOCESS
Dyeing
Spinning (Reduce thickness of roving)
Weaving
Finishing (chemical and mechanical)
Grey combing (Top ready)
Product prepare
Folding (inspection)
Length cutting and scathing
Stamping
Ready for export and domestic
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GREY COMBING DEPARTMENT
Greasy wool has import from South Africa and Australia.Order has been received in one and half month. Wool has reached at Bombay port and then by truck
it reached at DIGJAM. 20tone wool is in one ship.
The raw material (wool) received as per specification in different micron like 17.5 micron,18.5micron,19.5 micron and 22.5 micron. Micron has been measured in terms of length.17.5 is standardmicron as length wise.
Process of woolen fabric process of polyester
Fiber separation
Stretching
Releasing
CuttingGill Sliver(Combin
Card Sliver
(Gillin
Scoured wool
(Carding)
Raw-MaterialScourin
Tow cutting
Top
Gilling (3times)
Top
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Objectives of grey combing:-
To clean the greasy wool Increase the mean length of the fiber
Make in to the TOP form
This is the very first and initial division as a part of the whole process. In the grey combingthe raw material is greasy wool and polyester. So grey combing convert the wool andpolyester inform of top which made by sliver. So here wool is import from countries likeAustralia, south Africa and New eland and polyester supplied from RIL, IOCL and alsoimport from Germany. So grey combing has two ways to make the sliver:-
First from wool Second from polyester
First from wool
To remove all the undesired things and make the wool pure and ready for dye, there are fourprocesses to make top form:-
1) scouring2) Carding3) Gilling4) Combing
1) Scouring
This is the process by which dirt, grease, perspiration, salt and vegetable matters are removed fromthe wool by washing it in non-ionic detergent (namely IGSURF and ALPHOX) and soda ash. Thiswhole process contains five bowls, from which three bowls are used for washing the wool withdetergent (at 62C,60C,60C temperature respectively) and rest two is used for washing wool withclean hot water (at 55C temperature)
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The process of scouring contains four steps;
2) Carding
This is the process in which BURR and SHODDY are removed and cleaned it properly. Thewool have to pass over thirty five roller in carding process.Main object of carding is to remove vegetable matter, opened up bunches and fleeces for separationof fibers, conversion of web to silver form.
3) Gilling
Gilling is the process done before combing. In this, there is a comb like structure to blend differentquality of card sliver together and make fiber parallel to one another. The multiple fibers are mixedto reduce the variation in quality i.e. average length and fiber fineness in lot.Main function of Gilling is to make uniform sliver by drafting,
Three consecutive Gilling is given in the process to reduce the variation in quality the fibers;
Gilling-1 (ten carded slivers are fed to the machine and form one sliver)
Gilling-2 (5 slivers are fed)
Gilling-3
4) Combing
Combing process is done to remove remaining vegetable matters, naps and short fibers which can
create problems in spinning to generate drafting weave. The final product of combing is TOP andby product called NOIL.
Reopening (wool opened manually is reopened)
Washing (wool is washing with detergent & warm water
Squeezing (Pressure is given to the washed wool)
Drying (wool goes for dry in dried chamber at 90 C to 100C
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After Gilling the slivers are taken for post Gilling /top forming machine. Here the top gets desire wt.and be prepared for further process.
Second from polyester
Polyester tow is purchased from Reliance and Germany. Bell wt.appr.300 kgs. Length cutting as perrequirement.
For combing the polyester and make it in TOP form there are some processes are as follow:-1) TOW to TOP converter
A TT machine is used to convert the tow in a single step machine. The tow is continuousso it has to be cut according to the length of wool fibers. The polyester is slant-cut with arotating blade mounted on a drum.
2) Gilling
This process is performed to parallelize the fibers. After this it is converted in to top andsend to the dyeing and spinning department.
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Dyeing department
Wool tops and polyester tops are dyed separately. There are 10 dyeing machines. Each machinehaving 3 cells and each cell having 3 tops and weight of each top is 7 kg.
30% compressing for press the material. 41 C is given to machine for complete dye. Material dyeingis done in three forms:
Top dyeing
Yarn dying
Fabric dying
Some important point for dyeing
Wool is dyed at 100 C Polyester is dyed at 130 C Yarn is dyed at 120 C Light and medium shades are dyed for 30 minutes Dark shades are dyed for 45 minutes 100% wool can be dyed in the form of top or piece dyeing 100% polyester can be dyed either in top or piece. Polyester wool blend can be dyed in piece form only.
After dyeing the top, yarn and fabric they test the matching shade or color according to the customerorder if any color mismatched with the real one they again dyeing the raw materials and after allthese processes there is one another machine is called defelting machine. This machine is basicallyGilling the top because the dyeing tops are slivered after the dyeing.
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RECOMBING DEPARTMENT
During the dyeing process, certain degree of disturbance takes place, so removal of that disturbance
is required. For that re-combing process is required.
Objective of re combing1. to remove short fiber2. to remove dirt and naps3. to strengthen the fiber and make it parallel4. to enhance blending
Process of re-combing
Radio frequency (light shades)
Defelting
Gilling 4 times
Hydro extractor
Back wash (dark shades)
Comber
Gilling 2 times
Auto leveler
Top ready for spinning
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SPINNING DEPARTMENT
Raw for spinning is top which is final product of re-combing. Spinning applies draft to roving, thenapply twist to bind the fiber together to make yarn.
Process of spinning
Rubbing
Ring frame
Gilling 4 times
Single yarn steaming
Single yarn winding
Assembly winding
Twisting on TFO
Double yarn winding
Visual checking
Deliver to store
Roving
Double yarn steaming
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1) Gilling
Objective of Gilling
1. To make the fiber parallel by drafting,
2. To make the sliver even by evenization doubling
There are two sets of gill boxes1) GN-52) GN-6
1set = 4gillboxesNamely,
a, unicoiler with bollfiding
b, uni coiler with auto levelerc, bi coilerd, tri coiler
2) Roving
Objective of roving
1. To reduce the wrapping2. To make suitable package
Roving process include four machines, three machines for flyer frame and one for rubbing.Rubbing is end product for spinning preparatory.
3) Ring frameThere are 27 spinning machines. Spinning include ring frame. Operation of ring frame isdrafting and twisting. Ring frame include,
a) spindle capacity of ring frame400b) total spindle capacity of shed14800c) speed of the machine70009000 r.p.m
4) Single yarn steaming
Objective of single yarn steaming
1. To remove snarling effect from yarn2. To set yarn twist
5) single yarn winding
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Objective of single yarn winding
1. To remove fault from yarn2. To kept appropriate size of packets
This process is done by Autoconer machine. There are 5 Autoconer machines.
6) Double yarn steaming
Steaming is done to fix the yarn from doubling. It makes strong yarn. Here, 2 machines fordouble yarn steaming.
7) Double yarn winding (rewinding)
This is final process. There are two re-winding machines.
8) Assembly winding
Objective of assembly winding
3. To combine two single yarn to make one yarn
9) Twisting on TFO
Objective of TFO
Is to twist two yarn make one in such a way it looked like a single yarn. Process has two steps
1. S twisting with Z2. Z twisting with S
There are 20 TFO machines
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Weaving department
The function of weaving is to convert yarn into fabric.
Process of weaving
Yarn comes from spinning department and stored in yarn store, According to requirement theyprovide yarn to weaving department.
Sales department gives order to planning department and planning department gives order toweaving department.
In 1st process warping, in this process yarn will arrange in rank, process will start on drum and drumwill convert into beam.
In 2nd process drawing, beam is converting into loom according to length and design. collect designfrom design & development department In terms of graph. Vertically and horizontally (warp & wept)
design and arrange it accordingly.
Drawing
Winding
Grey inspection
Warping
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FOLDING AND FINISHING DEPARTMENT
Process of folding
The fabric is checked and the defects are flagged according to their type. White flags are put on thefaults which can be removed in the mending department. Red flags are put on the more severe faultswhich can not be removed and the fabric has to be cut from there.
Then the measuring, cutting, stamping and folding of the fabric is done. Fabric is ready for sale.
Final inspection
Stamping
Measuring $ cutting
Folding
Final inspection
Wrapping package
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Design & development department
Design is innovative and creative. Designer must expert to convert creativity into visual form.Designer makes visual communication, and it helps to satisfy the psychological and aesthetic needsof end user.
Sources of design
Direct feedback of customer Market survey International magazines which contains fabric cuttings. Designer intuition and past experience.
Design department makes sample through handloom and show that sample to sales department andfinally send it to production department for the further processing. For selection of domestic design
two conferences has been arranged. For export products have been prepared before one year.
Monitoring of design trends/seasonal needs and constant development work enable DIGJAM torespond rapidly to market demand and buyer needs. Higher standards of inspection at all stages,using the latest test equipment, ensures the near perfect quality and integrity of DIGJAM woolentextile multi terminal computers reinforce production control applicants.
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QUOLITY CONTROL
DIGJAM MILL having international lab for quality control. It has different machinery like:-1. Strength of thread is testing in one machine.
2. Testing the fiber length in average.
3. Microscope machine for testing diameter.
4. Air flow fiber for testing of stitching garment.
5. Fast instrument machine.
6. Drip meter.
7. Rubbing fast Check.
8. Pilling check.
9. checking(cross checking)
DIGJAM has been obtained its ISO 9001 certificate so it is highly conscious about qualityapart from various quality checks after each and every process, the sample items arescientifically rechecked several at the centralized quality control department. To check theraw materials several test are required i.e. yield % test, grease % test, dust and mud % test forthe checking of vegetable items. With the use of microscope, alimeter test is done to verifythe length parameter, average length, oil % test and diameter of wool top. The same processis used to check the quality of re combed top. In this laboratory fastness and moisture is alsochecked. There is an in house checking in yarn stage. Moreover, the strength of yarn andpilling check is also done. There is a steam testing machine to test the shrinkage.
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(QUOLITY IS DIGJAMS LIFE)
QUALITY POLICY
We, as a company are committed to:
Produce wide spectrum of quality fabrics/ products at competitive price to satisfy the need andexpectation of our valued customer. Our goal is to enhance customer satisfaction throughcontinual improvement.
This shall be achieved by:-
1. Implementing quality management system as per ISI/ISO 9001:2008 in the company in
letter and spirit.
2. Setting and reviewing objectives of various functions in the company.
3. Providing necessary training where applicable.
4. Reducing waste and defective % age during various stages of production.