Colony Textile Mills Essay

floor resolution Group is one of the leading and oldest fabric Manufacturing group in Pakistan. The 1st industrial venture of the group was in cotton ginning celestial sphere back in 1881. Gradually the group diversified in to flour milling in the early 1900s. First material rotate seed down was put up in 1946 under the name of addiction Textile move Limited. The Group further ventured in to Banking, Insurance, Cement, and Power Generation & Distribution. By 1952 colonisation Textile lollygags Limited was a composite textile plant with a 120,000 spindles, 1,500 sulks, and fabric finishing capacity in oversupply of 150,000 meters per day.Nationalization of 1972 took most of the business away, leaving Textile and Insurance in the Group. Presently, there argon two companies in the group, namely, colonization Textile Mills Limited (CTM) with about 195,000 Spindles, and Colony Industries (Pvt. ) Limited (CIL), consisting of 35,000 Spindles and 418 Air Jet Looms. breadth Lo oms 190cm 180 176 Cam +12 Dobby + 12 Crank (20 Looms with Batchers)210cm 24 24 Cam Looms (4 Looms with Batchers) 280cm 26 20 Cam + 6 Dobby 340cm 188 174 Cam + 14 Dobby Competitive Dimensions CIL is a very steady and only group that has 418 Looms in same place.This helps in fulfilment of coarse frames at high fixedness. If the looms are installed at different locations large orders stopnot be dish outed because of factors like communication barrier and increased comprise of conveyance etc. Anformer(a) unique thing CIL has is the Automatic D unexampleding in machine. When order of new shade is received it needs to be designed for the loom to work on. If manually this play is make the m compulsory to feed the new design in the loom would be nigh 16 hours. The time CIL takes to do the same task is just 2 hours with better efficiency.This automated machine is only available at CIL and increases order fulfilment speed. The power requirement for the setup of 418 looms, compr essor fleets and other support functions is 8MW. The cost of power i. e. electricity is reduced to a greater extent by manufacturing through its own power generation administration which produces 10MW through lifelike gas. Moreover for an uninterrupted supply of electricity CIL has its own grid station. likewise CILs own compressors fleet decreases the cost of raw material i. e. taut air which prevents the machinery from heating up and maintain humidity and temperatures. capacity mental ability or the business of looms greatly depends upon the caliber of fabric. If fabric is of high grapheme production volition be less. The reason behind this is high part fabric uses fine threads. fruit in like manner depends upon the number of threads employ in manufacturing. 6 million meters per month approx production has been recorded by CIL. Initially there were 120 looms at CIL. Capacity addition was make in March 2005 and 154 looms were added. Capacity addition for the 2nd time w as move intoe at the end of 3rd quarter by adding 144 looms make production capacity of 6. 0 million meters fabric per month.Core function and Value Added Services The core service of CIL is grey fabric manufacturing. They dont provide internal information of accounts, operations etc. to foreign people. However they provide samples to their clients which are sales support. Field support is also not easy in this weaving business but they do rectify the error within the specified time. Fail Safing techniques Automated interrogation sensors Automated motion sensors stop the affect of creeling, sizing and weaving whenever a thread breaks down or any error appears in the process. This prevents errors from increasing. Online recap SystemOnline Inspection system is a manual system by which errors can be checked by mills manager. The data is federal official to the system by operators and is evaluated by mills manager for removal of errors. During Production Checks Technicians and op erators are responsible for checking and removing the errors during production. later on Production Checks Inspection and folding segment rectifies error if it still exists earlier fisticuffs. After packing the order is haphazardly checked so that client gets error free order. Process natural selection The type of processes they are using at the most basic aim is Fabrication rocess that means Colony Industry converts their raw material i. e. raw tell to grey fabric. Grey fabric is the form of fabric in the beginning printing or dying. This process of fabrication is termed as Weaving in the terminology of Textile business. story flow is organized in the manufacturing plant by process technology known as batch shop. Yarn is retrieved from train of thought procurement surgical incision as the order is received for the production of grey fabric and then it is processed in the form of batches or order. Mill consists of 3 Units each having 2 Sheds which are control units. hiera rchy of authority is in Appendix.Each Unit is headed by Mills gutter and so on. Production in charge are responsible for 60, of age(p) technicians for 16 and Operators for 4-6 looms. Warping Creeling Quality Check Yarn High spin around Mill Low size of it Head Stock Warper Beams Drawing In Sizing Roll Inspection Bales Packaging Weaving Approve Pallets disapprove Storage Treatable Treat Yes No Waste No Flow chart Marketing department receives order and transfer production order to the mill. Mill staff plans the order and tells yarn procurement department for yarn purchase. This department purchases yarn from colonys spinning mill and other spinning mills.The yarn is not stored at the mill but it is received from the ascendent when needed. one time yarn is received by the mill it is sent to integral step check department for inspection where yarn is weighed and tested for hair and tension. If the yarn is not approved, it is sent back to the source other than it is transferre d to the next department. This yarn is in the form of spindles which is loaded on creeling machine manually. Then the process of warping starts in which these spindles are unrolled and rolled on the warping beams which are then transferred for sizing.In the process of sizing, starch and polyvinyl along with some other chemicals and water are cooked and applied to the yarn. This process makes yarn able to go through the next steps by increasing its strength and elasticity. After drying the yarn, ends are separated in a manner that they do not stick to each other. This dried yarn is rolled on short storage which has the size according to the width of the cloth known as sizing head stock. After the process of drawing in as explained previously, it is injected to the loom for the process of weaving. The temperature is controlled by a special system of compressor fleet.Once weaving is done, inspection of each inch of cloth is done for musical note assurance where decision is made regar ding acceptance, rejection and mending of cloth. After approval, it is sent for packing as mentioned in production order and if fabric is not approved, it is mended otherwise it is sent to the waste. Back Process In Warping, the whole set-up is of Ben-Direct Benninger V 1080/2400. Colony Ind. has 6 Warping machines with the Creel Capacity of 1080 each. Each machine is with the electronic sensors for the analyse of broken ends. In Sizing, Colony has the Ben-Sizetech Zell KVE, Creel 32 WW/4000 machines.Colony has 4 Sizing machines, 3 with the Head Stock size of 4 meters. Total Creel Capacity ranges from 16 (1 m/c) to 28 (1 m/c) till 32 (2 m/cs). The Sizing machine is with pre-wet technology with double dip sow-box. Colony has an additional facility of Beam Stacker which is not found anywhere else in Pakistan. Colony is weaponed with 2 Beam Stacker from Formia Nova of Italy with get of 65 veto holding the capacity of 195 no of beams for Narrow & 130 no of beams for Wider. DRAWING-I N Colony has the state of the art 2 Automatic Drawing-In machine which is found rarefied in Pakistan.One machine is from Staubli (Delta 110-4) which has the capacity of 150,000 ends/day filling with the speed of 140 threads/min. The 2nd machine is from EL&M S. P. A (Super Vega) which has the 80 threads/min filling speed. Weaving Colony has the total production of 6. 00 million meters fabric/month with 418 looms all of Toyota JAT 710 in production. In the 190 cm section (Narrow looms), they have 180 looms, 24 with the batching motions. sheep pen machines has the total capacity of 25k/shift/machine. Rolling machine is with the production of ten thousand meters fabric/shift/machine Quality Inspection/folding is the process for quality checks. In this process each inch of fabric is inspected. The quality of fabric depends upon the discretion of client and is checked according to the efficiency of loom stated in Production Order. Price also increases with the fineness of the fabric. Du ring the process if any daub is found than it is decided according to the nature of the defect whether to allow it or treat the fabric. Then fabric is categorized into three grades A, B and C.A is finest category and is considered to be of export quality, while B and C are of lower quality. They follow 4 point system which allows maximum of 4 errors and is world extensive accepted. Colony has fully equipped Quality Lab with all kind of testing equipments including the Uster examiner 4 for yarn checking. Quality Lab make sure that there is no compromise in the quality of the yarn used & the fabric produced. The whole set-up has the check points from Quality Department from Back Process to Article, from Inspection to packing, then resulting in the production of 1st class A-Grade fabric as committed.Colony has the Wrapping Reel from Mesdan Italy with the fashion model S-389 A used for the making of lea. It follows the ASTM stock ofD-1907-01. Auto Sorter is from Uster Switzerlan d with the Model PR 503 DR. Most Important machine in the Lab of colony is Uster UT -4 with the Model SE 400101-02100. Make of UT-4 is from Uster Switzerland for the checking of IPIs in the yarn. For the checking of Hairiness in the yarn, colony has the Hairiness Tester from Zweigle Germany with the Model G-567. To check the Tear Strength of the fabric, colony has the Tear Strength Tester from Zweigle Germany with the model FX-3750.Their primary focalize is quality because CIL is export based company. If quality is not up to the mark clients move to Bangladesh and China because they provide ratty products with low quality. Pakistani fabric is famous for its high quality and perfection. Recommendations 1. gross revenue of topical anaesthetic sector are dependent on few companies. The semblance of sales should be changed so that colonys risk is minimized. This ordain also help in improving performance as it will result in sale increase. 2. Sale per order should be considered and terminus should be the more worth of order, higher should be the frequency of order. 3. monitor systems that allows online communication and control of looms should be installed to manage the system more accurately. 4. Employees should be decreased by bringing in automated creeling machine which reduces the time by automatically removing the spindles once the thread is removed from them. 5. Operations focus should be on wide looms as they have said that these wide looms have generated greater inflows. 6. Capacity addition should be kept in view as it has been around 3 years now before the last addition was made. 7.Training of employees by sending them to technical institutes oversea should be done as fail safing technique to reduce the find of defect in the fabric. 8. Colony has fewer inflows in exports and greater in local therefore sales efforts should be engaged to increase local orders and increase inflows from exports. 9. Colony should use ingredient branding like they can ma rket their cloth by informing clients about the brand of Looms political party have installed. 10. Operations policy should be made and reviewed continuously. Every employee should be involved in designing the policy. Appendix