o ravi shekhar sem-v, nift delhi auro spinning mills – hall 5
TRANSCRIPT
O
Ravi Shekhar
SEM-V, NIFT DELHI
Auro Spinning Mills – Hall 5
1
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
2
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.
3
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
4
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.
5
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%
6
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
8
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