m52ged wahab final

M52GED ENVIRONMENTAL ENERGY MANAGEMENT

1 | P a g e

ENVIRONMENTAL MANAGEMENT FACULTY OF

BUSSINESS, ENVIRONMENT AND SOCIETY

M52GED

ENVIRONMENTAL ENERGY MANAGEMENT STUDENT NAME- Mr. SHAIK ABDUL WAHAB

Student ID- 3928736

Module Head- Mr. I Duckers

COVENTRY UNIVERSITY, 2011-12

Submission date- 1ST December 2011


2 | P a g e

Contents M52GED ......................................................................................................................................................... 1

ENVIRONMENTAL ENERGY MANAGEMENT .................................................................................................. 1

Module Head- Mr. I Duckers ......................................................................................................................... 1

COVENTRY UNIVERSITY, 2011-12 .................................................................................................................. 1

Submission date- 1ST December 2011 ........................................................................................................... 1

SuperNova Fashion Limited ........................................................................................................................... 3

Manufacturers and Exporters of Quality Clothing Worldwide ..................................................................... 3

INTRODUCTION ............................................................................................................................................. 3

PRODUCTS ................................................................................................................................................. 4

COMPANY PROFILE ........................................................................................................................................ 5

RAW MATERIALS ........................................................................................................................................... 6

MANUFACTURING ......................................................................................................................................... 6

Sewing ....................................................................................................................................................... 6

A. Industrial Sewing ......................................................................................................................... 7

B. Pre sewing functions ................................................................................................................... 7

C. Fabric Edges to be sewn .............................................................................................................. 7

D. Planning of sewing process ......................................................................................................... 7

E. Identification of seam lines ......................................................................................................... 7

Significant aspects of sewing .............................................................................................................. 8

Fabric Painting (Only for special orders) ................................................................................................... 8

Printing Process ......................................................................................................................................... 8

MACHINERY ................................................................................................................................................... 8

MAN POWER REQUIREMENT AND ANNUAL LABOUR COST ......................................................................... 8

ENVIRONMENTAL ISSUES .............................................................................................................................. 9

LEGISLATION .................................................................................................................................................. 9

NEW PROPOSITIONS .................................................................................................................................... 10

CONCLUSION ............................................................................................................................................... 14

REFERENCES ................................................................................................................................................ 14


3 | P a g e

SuperNova Fashion Limited

Manufacturers and Exporters of Quality Clothing Worldwide

INTRODUCTION

SuperNova Fashion was constituted by Mr. Eashwaran (founder and adviser) who has sound

background and 20 years of experience in Textiles and was formed in the year 1999, since there

we have grown from a small company to one of the best company in India, after his retirement

from appex management now the next generation take the seat of the concern.

WHY US?

We have marked a distinguished position for ourselves in this competitive market

by providing finest quality products as per the latest fashion trends. Our products are widely

recognized for its quality, cut and designs inputs.

We are ahead of our competitors due to following features:

* Quality standards

* Competitive prices

* Innovation

* On time delivery

* Expert product solutions

* Highly skilled professionals

* Stock holding and management upon request

* Short time deliveries

* Handling minimum quantities

* Vertical manufacturers

* Eco friendly suppliers, processes, products

* Skin friendly products Okeo Tex certified vendors

* Organic certified vendors GOTS, OE100

* Complaint factories WRAP, SA 8000.

OUR SERVICES

Sampling Development and R&D - The samples are made to clients specifications

and our innovative creation based on fashion trend in the global market.

Price Negotiation - Competitiveness, Transparency.

Vendor selection / Order placement - Choosing the vendors according to the

product specification and order placement accordingly.


4 | P a g e

Order follow up - Periodic production status, Right from laboratory test with

international accredited lab and quality control at various stages from fabric

to Final Random Inspection.

Logistics and Shipment follow up - Ensuring correct shipping documents and

prior approval from the clients before and post shipment ensuring trouble free delivery.

Buyer & Seller meet - Planning and organizing the buyers visit to any our factories.

Buyers will be taken to vendors and their factories in order to make

personal assessment about the vendor.

Market information and Fashion trend - Periodical market information such as

competitor activities, socio-political activities, industrial problems,

currency fluctuations etc., will be informed to the clients.

Personalized Follow Up - Frequent visiting across the globe to have a personal

encounter with the Company's long list of clients ensures instantaneous updating

of fashion, trends, developments and consolidation clubbed with expansion.

PRODUCTS

Mens wear - Shirts, Boxer shorts, Pull on/Constructed waistband Shorts and pants, Trousers,

Jeans, Vest Jackets, T-shirts, Jackets (Quilted/Lined), Vests, Over t-shirts, Zipper/Button polo,

Mock neck, Crew neck, Tank top,

Boxer shorts, Intimates, Bath robes, Track suits

Womens wear - Shirts, vests, Skirts, Quilted skirts, Double layer Shorts,

Pull on pant, Capri, Bias jumper, Romper, Jump suits, Trousers, Jeans, Scarf

Mock neck, Crop tops, Basic T-shirts, Poloshirt, Skirts, dresses, Shorts, Pull on pants, Scarf,

Pinafore gowns, Pyjama sets, Pants, Capri, Intimates, Bath robes, Tank top, Track suits,

Sweatshirts, Night wears, Bikini wear, Shoulder cover

Kids wear - Shirts, Shorts & Pants, Jump suits, Capri, T-shirt, Shorts, Dresses, Jumpsuits,

Intimates

Infant wear - Romper, Body-suit, T-shirt, Intimates

Home Textiles - Napkins, Towels, Bed covers, Pillow covers, Bed sheets, Curtains, Table

cloths, Placemats

FABRICS

Woven fabrics - Poplin, Drill, Denim, Dobbies, Flunnel, Suitings, Satin, Voile, Canvas,

Jacquards, Yarn dyed check & Stripes, Corduroy

Knitted fabrics - Single jersey, double Jersey, Interlock, Single rib, Double rib

Derby rib, Flatback rib, Airtex, Pique, Honeycombed, Waffle, Fleece, Pointel, Velour, Terry,


5 | P a g e

Polar fleece, Jaquards, Herringbone, Flat knit, Feeder strippers,

Auto & Engineered Stripes

Contents - Cotton, Polyester, Modal, Bamboo, Viscose, Linen, Hemp, Rayon

Polyamide, Organic Cotton, all with lycra & without lycra and combination blends of all above.

SuperNova Fashion Ltd will always try to pursue good workmanship. With over 10 years of

experience in the competitive textile industry, our proficiency as an apparel manufacturer allows

us to provide our customers with clothing that is the absolute top class in quality and durability.

Our certain range of clothes is hand-made by our finest tailors for a personal touch.

The company employs a 100 odd people from all races on various categories such as skilled,

highly-skilled, salesmen, cashiers, drivers, storekeepers and so on. The company factory is

located in the outskirts of Tirupur (TeOnline), India

Our unit is divided into 4 sections. Sections A consists of machineries required for the

production, finishing and packaging process, consumes more amount of energy compared to the

other three sectors. Sections B contains of a canteen, rest rooms for both male and female and

a small lounge for relaxation and recreation. Section C contains office rooms and medical

amenities. Section D consists of a midsized go down for the purpose of storage for raw materials

and the finished products along with the waste yarn that are to be recycled and is a part of an

old warehouse. All the infrastructures in the respective sectors have fire exists in case of

mishap.

COMPANY PROFILE

BASIC INFORMATION

OWNERSHIP & CAPITAL

Year Established: 1999

TRADE & MARKET

Main Markets: 1. North America 2.Eastern Europe

Company Name: SuperNova Fashion Ltd

Business Type: Manufacture, export and Wholesale

Product/Service (We Sell):

Mens Wear, Women’s wear, Kid’s wear etc.

Product/Service (We Buy):

Mentioned below in detail

Number of Employees: 103 People (Permanent and temporary, contracted)


6 | P a g e

3.Africa 4.South America 5.Northern Europe 6.Southern Europe

Total Annual Sales Volume: INR 400 Million to INR 600 Million

Export Percentage: 91% - 100%

FACTORY INFORMATION

Contract Manufacturing: OEM Service Offered, Design Service Offered, Buyer Label Offered

RAW MATERIALS

We import high quality yarn, threads, zippers and buttons from India and Bangladesh. In all we

have 12 registered vendors for raw materials. We procure mostly polyester and cotton yarn.

The price of the raw materials would be estimated upon the type of order we get. If it is a large

order, the raw materials we purchase is about 15 Million Rupees (inclusive of taxes, labour

charges, handling and transportation).

S. No Types of Raw materials Units Quantity

1 Yarn

Cotton

Polyester

Nylon

Tonnes Tonnes Tonnes

75 54 14

2 Buttons

Round

Trouser

Jeans

Special

Pcs 16million 4.5 million 3 million 500,000 average Or as per order

3 Zippers

Trousers

Jeans

Pcs 2.2 million 3 million

4 Threads-all colours Tonnes 12

Table 1- Raw Materials

MANUFACTURING

Sewing The basic process of sewing involves fastening of leather, fabrics, furs with the help of

needle and threads. Sewing is one of the important processes in apparel making. Industrial

sewing machines do most of industrial sewing. The cut pieces of a garment are mostly tacked,

http://www.teonline.com/knowledge-centre/apparel-making.html

http://www.teonline.com/knowledge-centre/sewing-process.html


7 | P a g e

or stitched temporarily at the initial stage. The complex parts of the machine then pierces thread

through the layers of the cloth, interlocking the thread.

A. Industrial Sewing

Looks to be a simple process, industrial sewing is quite complex involving many

preparations and mathematical calculations for the correct seam quality. Quality sewing

also depends on the sound technical knowledge that goes into designing pattern and

making. Flat sheets of fabric having holes and slits into it can curve and fold in three-

dimensional shapes in very complex ways that require a high level of skill and experience

to manipulate into a smooth, wrinkle-free design.

B. Pre- sewing functions

Before the actual task of sewing begins, there are certain other tasks that have to be

taken care of which can be termed as fabric handling functions ply separation, placing

the fabric on working table, guiding the fabric towards sewing needle and tension control

of fabric during the sewing process. While ply separation, stacks of fabric plies are

sequentially positioned with the help of some feeding apparatus in an unloading position.

The topmost ply in such a stack is individually and sequentially separated from the stack.

In the process, an edge of the separated fabric is presented between the jaws of a

gripping device. A proximity switch checks the space between the gripper jaws. When

this spacing confirms that only one fabric ply is in place between the jaws, the single ply

is transferred over the receiving end of a conveyor for further processing.

C. Fabric Edges to be sewn

Two basic types of stitches- one is that are for joining two parts of cloth together and the

other one is done for decorative purposes. Sometimes, both types of stitching have to be

done for eg, a pocket has to be joined on three sides with the apparel as well as it may

be given some decorative stitches too. At what points and which type of stitching has to

be done- all such information is stored digitally on automated devices through CAD and

properly sewn.

D. Planning of sewing process

Sequence of seams to be stitched is checked before you start sewing. Which part will be

joined first, what stitches will follow one another, etc. are decided. However, some

stitches have to be necessarily done before or after another stitch. Like mentioned

above, the decorative stitches must be done first followed by the joining stitches

E. Identification of seam lines

Sewing process is performed on seam lines situated inside the fabric edges, some mm

inside the fabric's outer line. For the straight lines, the seam line is found by transferring

the outer lines inside the fabrics and the intersection of these lines makes the vertices of

the seam line. Hence, seam line is parallel to the outer edge and the distance between

the two has to be determined as it is different for different parts of the cloth. Seam

allowance is the area between the edge of the fabric and the line of stitching. It is usually


8 | P a g e

1.5 cm away from the edge of the fabric. Seam allowance is usually 2.5 cm or more for

standard home dressmaking. Industry seam allowances vary but they are usually 0.6 cm.

Significant aspects of sewing

There are certain aspects that have to be carefully considered while the sewing process as they

are very crucial for high quality sewing.

Thread tension and consumption

Presser- foot displacement and compressing force

Needle penetration force measurement

Fabric Painting (Only for special orders) Different fabrics such as apparel fabrics or home furnishing fabrics can be crafted beautifully

using fabric painting. This technique can also be used for decorating denim jeans, shirts, skirts,

t-shirts and jackets.

Printing Process The Dyes used for printing mostly include vat, reactive, naphthol and disperse colours which

have good fastness properties. The pigments, which are not truly dyes, are also used

extensively for printing. These colours are fixed to the fibre through resins that are very resistant

to laundering or dry-cleaning. Pigments are among the fastest known colours and are effective

for light to medium shades. If used for applying dark colours, they may crock or rub off. Cheap

prints are made from basic colours mixed with tartar emetic and tannic acid but they are not

acceptable in today’s market.

MACHINERY

S.NO LIST OF MACHINARY QTY

1 Sewing Machine 20

2 Embroidery machine 1

3 Cutting machine for garments 1

4 Industrial Sewing machine 1

5 Household sewing machine 10

6 Ironing machine 10

7 Steam Press 5

8 Hemming Machines 2

9 Denim Sewing Machines 3

MAN POWER REQUIREMENT AND ANNUAL LABOUR COST

http://machinery.fibre2fashion.com/1/sewing-machine/


9 | P a g e

S.NO Description Req. No.

Annual Salary (INR)

1 Plant Manager 1 350,500

2 Production and Technical manager

1 350,500

3 Finance and administrative manager

1 245,500

4 Commercial manager 1 200,000

5 Chemist 2 200,000

6 Executive secretary 1 200,000

7 Production supervisors 3 200,000

8 Mechanic 3 200 per day

9 Electrician 3 200 per day

10 Skilled operators 25 180,000

11 Unskilled workers 55 150,000

12 Accountant 2 180,000

13 Purchaser 1 200,000

14 Sales man 3 500 per day

15 Cashier 1 180,000

Table 2-Manpower Required

Any additional worker employed at per day basis.

ENVIRONMENTAL ISSUES

Environmental issues during the operational phase of textile manufacturing primarily include the

following:

· Hazardous materials management- Dyes and paints.

· Wastewater- Chemical water but drained properly.

· Emissions to air- Vapours of paint and dyes

· Energy consumption- View to minimise working more shifts during daytime.

· Solid and liquid waste- waste extra cloth sold as cleaning

LEGISLATION

The Health and Safety at Work Part 8.

The Safety Representatives and Safety Committees Regulations 1977


10 | P a g e

The Management of Health & Safety Regulations 1992 amended 1999

The Health & Safety (Consultation with Employees) Regulations (HSCEC) 1996

The Information and Consultation with Employees Regulations 2004. (house)

Contract Law

Employer will ensure the employees’ health, safety and welfare.

Inspecting the workplace.

Investigating potential hazards.

Investigating reportable accidents, cases of diseases or ill health and dangerous

occurrences. It is good practice to investigate all accidents that occur in the workplace.

Besides this there is the common laws and regulations.

NEW PROPOSITIONS

The propositions made from 2006-2011 to mitigate the amount spent, environmental

issues.

YEAR 2006

Economic/Environmental

Driving force

Strategy Yearly

accomplishments

Future plans

Climatic change and the

increase in utilisation

cost

Improved

energy

efficiency will

achieve the

target of

reducing

Group

energy

consumption

by 19% from

that of the

2006

calendar

year by

2011.

Accomplishment of

46% reduction in

energy

consumption with

mitigation of utility

price increase and

daytime machinery

operation.

Solar panels

installation

could be

possible.


11 | P a g e

Management and

corporate social

responsibility auditing

ISO

9001:2005

accreditation

of site.

Site now

accredited to ISO

9001:2005 with

mature

management

Achieve

EMAS

accreditation

within 2

years.

Noise and air emission The odours

from the site

should not

impact the

boundaries

beyond the

site.

Reduction of

complaints is

achieved by

proper techniques

of abatement,

mitigating, odour,

emission, noise

with upgraded

treatment

processes.

Upgraded

odour control

and wet

scrubbing

plant with bio

filters. Sound

proofing

sewing unit.

Land fill availability and

costs

This can be

achieved by

avoiding

waste

creation and

there by

employing

the beneficial

technique of

reuse.

Another

method is to

not keep

excess stock.

Composting or

beneficial

application

account for 80% of

biodegradable

waste. The sale of

by-products has

also replaced

landfill.

Shaving

reduced and

alternate

application of

waste

recovery in

case of more

waste and

thereby

increasing

profit by 6%.

Table 3-New Propositions-2006

YEAR 2007

Taking into account the environmental drivers such as climatic changes and utility costs we aim

to start using renewable sources of energy. This is achieved by generating thermal energy from

the waste. This will tremendously reduce gas purchase and also lessen waste disposal. Both the

compliance and feasibility trials are successfully completed. The risk assessment is planned with

the detailed design of the application process and the methods on how to achieve it with

minimum cost.

YEAR 2008

Economic/

Environmental

Strategies Yearly

accomplishments

Future plans


12 | P a g e

Driving force

Climatic change

and the increase in

utilisation cost

Improved energy

efficiency will

achieve the target

of reducing Group

energy consumption

by 10%.

Reduced Carbon

Dioxide Emissions

and improved

efficiency through

application of radiant

heating, variable

speed drive

installations, reduced

water temperatures.

Continued efficiency

gains especially heat

recovery systems,

application of

variable speed

drives, boiler

decentralisation and

radiant heating

applications.

Auditing

management and

corporate social

responsibility

ISO 14001:2007

accreditation of site.

All sites are now

accredited to

ISO14001:2007 with

optimise

management

system.

Reduce risk to

forthcoming

environmental

liability legislation.

Seek business case

for EMAS

accreditation.

Storage systems Proper storage of

fuels, waste and

raw materials pre

production and post

production.

Raw materials used

for production are

stored efficiently

under cool dry

containers. The

products produced

are packed and

sealed and finally

stored onsite for

transport two times a

week.

This ensures a

proper management

system and low

vulnerability towards

laws and also

improves the

aesthetics of the site

windows.

Table 4-New Propositions-2008

YEAR 2009

Economic or

Environmental

Driving force

Strategized

objective

Yearly

achievements

Futuristic action or

anticipated

deviation

Climatic change

and the increase

in utilisation cost

Improved energy

efficiency will

achieve the target of

reducing Group

energy consumption

by 10% in the year

2008.

Reduced Carbon

Dioxide Emissions

and improved

efficiency through

application of

radiant heating,

variable speed

Continued efficiency

gains especially heat

recovery systems,

application of

variable speed

drives, boiler

decentralisation and


13 | P a g e

drive installations. radiant heating

applications.

Land fill

availability and

costs

Avoid landfill by

avoiding waste

creation, employing

beneficial reuse and

recycling.

The reduction of

shavings by

precision splitting

and sale of

trimmings.

Registered and

compliant to

Packaging

Obligations.

Minimise landfill.

Thermal Energy

Plant with direct

waste heat recovery.

Sale of all

recyclables remains

a target

Table 5- New Propositions-2009

YEAR 2010

Concentration on yield improvement, along with the strategies;

SuperNova Fashion Ltd area yield improvement programmes improve company performance by

maximising the quality. View to keep the value of the business high, best quality yarn

manufacturers across the world especially in India. Sewing operation facilities need to remain

focused on maximising company performance.

SuperNova Fashion Ltd Yield Improvement Programmes offer a low risk strategy to improve

profitability in a very short time frame. Area gains of 4% to 8% or more are achievable,

depending on the type of clothes produced and the degree of comprehensive perception and

control of existing products and process. The programmes are carried out systematically in

collaboration with the operational team. A key element of the success rate is training labour,

concentrating on using raw materials economically, maintaining quality standards, maintaining

and improving output rates. As well as significant area gains, the programmes also contribute to

easier production management and enhanced competitive advantage.

YEAR 2011

The money saved from the profit, low energy consumption, low waste strategy year by year from

2006 to 2010 is used to increase the buying of raw materials in order to supply too many other

customers in 2010 and also to build up an efficient pre treatment facility for water discharge. The

effluent and the contaminated water are directed into the water treatment system thereby

cleaning the discharge making it contaminant free and reusing that for industry purposes.

Accreditation of clean water act and clean air act of 2010 and also ISO 14001:2010 adhering to

the legislation is prioritized and all employees of all positions are knowledgeable of the laws and

regulations of the company along with its policies and work towards a better futures.


14 | P a g e

CONCLUSION

SuperNova Fashions Ltd has undergone major changes in its policies accordingly so that the

environmental impacts are reduced thereby increasing the profit by employing new techniques.

The company has prioritized the effective strategies such as the reduction energy over

consumption, water treatment facilities to mitigate environmental problems and also has

invested a lot in saving energy keeping in mind the depletion of natural resources. We also have

a new 5 year plan in place and if we act accordingly we hope to maximise our profits by 8-18%.

REFERENCES

house, E. p. (n.d.). Retrieved from http://www.edym.com/en/

Safety, H. a. (n.d.). Retrieved from http://www.hse.gov.uk/textiles/audit/part8.htm

TeOnline. (n.d.). Retrieved from http://www.teonline.com/knowledge-centre/textile-

processes.html

m52ged wahab final

Documents

land fill

heat recovery

variable speed

avoiding waste

radiant heating

annual labour

quality clothing

radiant heating