INDURISTRIAL VISIT REPORT

CONDUCTED AT

RSWM LIMITED BHILWARA, RAJASTHAN

&

SANGAM INDUSTRIES LIMITED BHILWARA, RAJASTHAN

Submitted in Partial Fulfillment of the requirements for

MBA (BE)

SUBMITTED TO: DR. SHIVDAYAL SINGH HEAD DEPT. OF ECONOMICS

SUBMITTED BY: sourabh sarda MBA(BE).

MAHARISHI DAYANAND SARASWATI UNIVERSITY DEPARTMENT OF ECONOMICS, AJMER 2009-2011

SYNOPSIS
1. Acknowledgement. 2. Introduction 3. Rajasthan Spinning And Weaving Mills Ltd. 4. Sangam Group 5. Bibliography

ACKNOWLEDGEMENT
First of all I would like to thank all the faculty members of the department for conducting the industrial visit. I show my gratitude towards Dr. Shiv Dayal Singh (Head - Economics Department) for his continous guidance in bringing out this informative industrial visit. I would also like like to give my sincere thanks to all the other faculty members, for providing their necessary guidance and support in bringing the concern of the industries we visited.

Nisha Parwani MBA (BE)- Sem II

INTRODUCTION
The management courses require a close practical study of successful leading industries. Keeping in view this vital aspect of management studies , a industrial visit was organized. Location : Bhilwara Industries Covered: RSWM & Sangam Group. Nature Of Industries : Textile (Spinning & Weaving Divisions.) Today most of the industrial giants find it difficult to cope up with the dynamic market scenario. There is need for competitive strategies and policies to face the global competition. The recent economic meltdown , has caused many industries to shut down and many survived running with a correct mix of cost efficiency, right product strategy, etc. Many of the corporate are not being able to adjust themselves in the dynamic economic environment which ultimately results in lower activities in capital market. Prices of equity are not stable and so on. The industry, the government and the capital market should work as a well knit team, to put economic and industrial activities back on track.

Bhilwara emerged as India's largest manufacturer of suitings, fabrics and yarn. Its share in the polyester/viscose fabrics (suiting) sector is around 50 per cent in India. The phenomenal growth of the textile industry is something interesting if seen in the context of a similar scenario elsewhere in the country. There is nothing special about Bhilwara to have come to the top position in the country except the fact that the entrepreneurs are a unique lot with enthusiasm to have something of their own even though the initial troubles happen to be serious.

RAJASTHAN SPINNING & WEAVING MILLS LTD.

CONTENT 1 2 3 4 5 6 7 8 9

PARTICULARS INTRODUCTION MANAGEMENT TEAM MISSON AND VISION MILESTONES ACHIVEMENTS PRODUCTS MANUFACTURE PROCESS TYPES OF YARN CSR

Introduction

RSWM Limited, the flagship Company of LNJ Bhilwara Group, is a professionally managed, progressive and growth-oriented and one of the largest textile manufacturer in the country, primarily producing synthetic, blended, mlange, cotton & specialty yarn, fabric and denim. RSWM was established in 1960, an IS/ISO 9001:2001 and SA 8000:2008 accredited Company, has 8 state-of-the-art manufacturing plants which moved from strength to strength and today, it operates about 3,60,000 spindles, having 1,00,000 MTA yarn capacity. It is equipped with in-house fabric weaving and processing facilities of about 35.6 MMA for fabric and denim fabric. RSWM is self - reliant in Captive Power Generation of 46 MW that feeds all its integrated units spread across the state of Rajasthan. Modern technologies and world class skills have enabled the Company to produce the finest quality adhering to stringent international norms. The main competitive strength of the Company is its innovative product range that includes specialty, functional, technical and eco-friendly yarn and fabric alongwith basic and commodity products. The Company recently has shifted its focus to produce more and more natural textiles in order to meet the emerging needs of the market. The Company holds the prestigious Three Star Export House status and has received Export Awards from the Synthetic and Rayon Textiles Export Promotion Council consecutively for several years. The Company is a recipient of the Rajiv Gandhi National Quality Award received from the Bureau of Indian Standards for the years 2006 and 2007. RSWM has also received "Niryat Shree" - Certificate of Excellence (Non-SSI) award for the catagory of textile.

Gulabpura Unit :
Established in 1973, the Gulabpura was among the first units to be set up by the Rajasthan Spinning & Weaving Mills Ltd. The Gulabpura unit is the manufacturing base for the highly popular and well known Mayur Suitings brand- a market leader right across the country. It is the first textile unit in India to be awarded ISO. It has the exclusive rights to technology that goes into the production of Flame Retardant Fabric. The plant produces Dyed yarns and fabric blends of Polyester, Viscose, Acrylic, Lycra, Wool, polyamide, Flex and Modal. It is the most versatile plant manufacturing Yarn and Fabrics and a diversified product mix. This unit also specializes in integrated Fabric that uses yarns from man-made fibres & the exclusive rights for spinning Tencel Yarn in India. 1985, this unit started exporting Polyester- Viscose Yarn to Europe. Today 35% of its yarn output is exported .

MANAGEMENT TEAM
Name A N Choudhary Arun Churiwal D N Davar J C Laddha Kamal Gupta L N Jhunjhunwala Prabhakar Dalal Prakash Maheshwari Ravi Jhunjhunwala S C Garg Shekhar Agarwal Surender Gupta Surender Gupta Sushil Jhunjhunwala T Dev Joshi Y C Gupta Designation Director Managing Director & CEO Director Executive Director & CFO Director Chairman Emeritus Nominee Director Chief Executive Chairman / Chair Person Chief Executive (Melange Yarn) Vice Chairman Co. Secretary & Compl. Officer Secretary Director President (Corporate HR & OD) Chief Executive (Denim)

Mission and Vision

Mission
With unique insight into consumer behavior, we strive to offer the best. Following distinct business strategies, the company will continue its tradition of manufacturing the finest products.

Vision
RSWM envisages itself as a trend setter of the textile industry. It is committed to introduce innovative products in the industry which will set new standards.

PROUD TO BE INDIAN PRIVILEDGED TO BE GLOBAL

MILESTONES

RSWM limited is the new name for Rajasthan Spinning & Weaving Mills Ltd. RSWM has initiated a Rs. 900 crore expansion plan. Its Denim & 46 MW Captive Thermal Power Plants have commenced operation. RSWM expands their spindle capacities at all the plants. RSWM was recently felicitated with Rajiv Gandhi National Quality Award. RSWM announced the acquisition of Cheslind textiles Ltd., a Bengaluru based textile unit. RSWM ropes in Salman Khan as brand ambassador for Mayur Suitings.

ACHIEVEMENTS

RSWM is the winner of SRTEPC Highest Export Award for polyester / viscose yarn exports for the last 13 years. RSWM bagged The 2007 Excellence Award for Financial Performance and Analysis instituted by Rajasthan Chamber of Commerce & Industries, Jaipur Rajiv Gandhi National Quality Awards Commendation certificate in Large Scale Textile Industry to Banswara and Kharigram unit in year 2006 and year 2007 respectively. RSWMs Rishabhdev unit bagged National Export Award, and the SRTEPC Excellence award for highest production in export of 100% Polyester Spun Yarn An advanced machinery repertoire from world leaders, ensures flawless quality and more versatility at each and every stage. Our Banswara plant certified for producing and selling Organic Cotton yarn from "Control Union Certification" (formerly known as SKAL) Certificate of "Global Organic Textile Standard" (GOTS) for producing and selling 100% Organic Cotton yarn to our Banswara plant.

 Certificate of "Organic Exchange" (OE)for producing and selling Blended yarns with Organic Cotton to our Banswara plant Certificate of SA-8000 speaks that all the material produced by the RSWM Ltd. by respecting the environment and ethical values for our Banswara unit. Certificate of Fair Trade from Fair Trade Labelling Organisation for producing selling 100% Fair trade cotton and its Blended yarn, for Banswara unit. Certificate of Global recycle standards (GRS) for producing selling the recycled cotton and Blended yarn with and without recycled man made fibers. Having Oekotex standard 100 certiifcate for most of the products

Products

Yarn
RSWM offers one of the broadest range of products in terms of fibre blends, counts and shades. Fibres possessed by the Company include polyester, viscose, acrylic, cotton, wool, rayon, silk, polyamide and linen. In addition the Company produces a range of speciality products made out of both unorthodox fibers.

Fabric

RSWM manufactures a range of blended suiting fabric and has a significant presence in the domestic market with its Mayur brand. Apart from this, this segment includes a fabric processing plant in Mordi (Rajasthan).

Denim:

RSWM ventured into Denim Fabric manufacturing business in line with strategy to move to higher value-added segments for wider based growth in the future. The Company has plant to focus on producing high-end Speciality Denim fabric which has better realization and demand in the international market.

Yarn manufacture does in many steps, Every step contain self machine process for completing own task. This process does with the help of heavy and costly imported machines. We can understand the process of yarn manufacture by following steps:

Mixing: This is the first step to make a mixture of two material

polyester and wise core. Cotton is a hygroscopic material hence it easily adopts to the atmospheric air-conditions. Air temperature inside the mixing area should be more than 25 degree centigrade and the relative humidity (RH%) should be around 45 to 60 %, because high moisture in the fiber leads to poor cleaning and dryness in the fiber leads to fiber damages which ultimately reduces the spin ability of cotton.

Blow room: With all harvesting methods, however, the cotton

seed, together with The fibers, always gets into the ginning plant where it is broken up into trash and seed-coat fragments. This means that ginned cotton is always contaminated with trash and dust particles and that an intensive cleaning is only possible in the spinning mill.

Nep content increases drastically with mechanical harvesting, ginning and subsequent cleaning process. The reduction of the trash content which is necessary for improving cotton grade and appearance unfortunately results in a higher nep content level. The basic purpose of Blow room is to supply small fibre tufts clean fibre tufts Homogeneously blended tufts if more than one variety of fiber is used to carding machine without increasing fiber rupture, fiber neps , broken seed particles and without removing more good fibers. The above is achieved by the following processes in the blow room Pre opening pre cleaning mixing or blending fine opening deducting

CARDING : Carding is a
process which is meant for upgrading the cotton raw material so that the following yarn properties will improve compared to the normal carded yarn.

THE PURPOSE OF CARDING: to open the flocks into individual

fibers, cleaning or elimination of impurities, reduction of neps ,elimination of dust , elimination of short fibers , fiber blending , fiber orientation or alignment and sliver formation.

RINGS And TRAVELLERS

In most cases, the limit to productivity of the ring spinning machine is defined by the traveller in interdependence with the ring, and yarn. It is very important for the technologist to understand this and act on them to optimize the yarn production. PROCESS PARAMETERS IN

Drawframe is a very critical machine in the spinning process. It's

influence on quality, especially on evenness is very big.If drawframe is not set properly, it will also result in drop in yarn strength and yarn elongation at break.The faults in the sliver that come out of drawframe can not be corrected . It will pass into the yarn.

Ringframe
Ringframe Technology is a simple and old technology, but the production and quality requirements at the present scenario puts in a lot of pressure on the Technologist to select the optimum process parameters and machine parameters, so that a good quality yarn can be produced at a lower manufacturing cost.

Auto conor:
it makes big corns by small

WINDING :

Ring spinning produces yarn in a package form called cops. Since cops from ring frames are not suitable for further processing, the winding process serves to achieve additional objectives made necessary by the requirements of the subsequent processing stages. Following are the tasks of winding process : Extraction of all disturbing yarn faults such as the short, long thick ,long thin, spinners doubles, etc Manufacture of cones having good drawing - off properties and with as long a length of yarn as possible paraffin waxing of the yarn during the winding process introduction into the yarn of a minimum number of knots achievement of a high machine efficiency i.e high produciton level
.

DOUBLING:
In this step a combination of thread made up by two thread, this is to improve the thread quality.

COLOR :
To make colorful thread, this process applies on simple thread.

ESTEEM MACHINE :
This machine is used for make dry to colorful thread after dying process, by esteem process.

There are three major categories of yarn:

1.

Gray Yarn

2.

Dyed Yarn

3.

Malange Yarn

Corporate social responsibility

In a culture, where the earth is referred to as Mother, caring for the environment is ingrained. In caring for the earth we are committed to leaving our children and the generations to come a clean, green earth. A promise that we live by and live up to in everything we do. At every step in the manufacturing process, we employ eco-friendly processes not just to abide by laws but also to sustain and take forward the 'green' traditions that form a rich part of our heritage. Effluent treatment is carried out using the latest state-of-the-art technology. All the water used in fabric dyeing and finishing is recycled for use in the processhouse and in horticulture. We are continuously greening all our plants, residential and other facilities, planting thousands of saplings every year. Environmental care is executed with an eye for detail. The Banswara unit has over 42,000 square metres of greens, with over 50,000 plants having been planted on the campus and an exquisite 11-acre orchard surrounding an artificial lake. The Banswara unit was accorded the best plantation award in Rajasthan.

SANGAM INDUSTRIES LIMITED

CONTENT 1 2 3 4 5 6

PARTICULARS INTRODUCTION GENERAL INFORMATION MANAGEMENT TEAM PLANT CAPACITY PRODUCT OVERVIEW PROCESSING ACTIVITY

INTRODUCTION
A Textile Conglomerate, the Bhilwara (Rajasthan) based Sangam Group of Companies (SGC) is today a name synonymous with excellence in textiles. It is a "Complete Textile House" that is diversified into spinning, weaving, knitting, flock fabric and processing having state of art. It is a prominent and leading manufacturer, exporter and supplier of worldclass Suitings, Denim fabric, Flock Fabrics and Cotton and synthetic yarns from India.

It offers a product range that defines quality, superiority and unmatched excellence. It is a professionally managed group having complete technical expertise and a web of ultra-modern textile production machines. It is an IS/ ISO 9001:2000 certified company producing world's finest fabrics.

Based in textile city, Bhilwara, it has one of the largest unit in India to produce dyed yarn using state-of-the-art machinery. The company exports its premium product range to Turkey , Belgium , Spain , MiddleEast, and various other countries.

GENERAL INFORMATION
Group : Flag Ship Company : Constitution : Date of Establishment/Incorporation : Date of commencement of business : Line of activity : Capacity : Sangam Sangam (India) Limited Public Limited Company 29.12.1984

02.05.1985

Composite Textile Unit. Spindles Rotors Weaving Machines Knitting Machine Process House Annum Home Furnishing Annum Captive Thermal Power Plants : 1,93,920 : 2464 : 257 : 12 : 28 mn. Metres Per : 2.5 mn. Metres Per : 31 MW

Registered Office : E-mail : Location of Factory/shop/ principal place of business :

Pur Road, Bhilwara 311 001 bhilwara@sangamgroup.com (1) Vill Billiya, Chittor Road, Bhilwara. (Spinning) (2) Vill Atun, Chittor Road, Bhilwara. (Weaving & Processing) (3) Vill Sarari NH-79, Bhilwara. (Spinning)

MANAGEMENT TEAM
BOARD OF DIRECTORS Shri RP Soni, Chairman

Shri SN Modani, Managing Director

Shri VK Sodani, Executive Director

Shri Ramavtar Jaju, Director

Shri A. Karati, Director

Shri Sunay Mathure, Nominee Director of ICICI Venture

PLANT CAPACITY

SPINNING UNIT: One of the largest unit in INDIA for making export quality Polyster /Viscose dyed yarn. Now the company produces export quality cotton yarn also. After installation of initial spindleage during 1995 through many times expansions, the Company has raised its capacity to 193920 spindleage. The machineries are being procured from suppliers of national/international repute i.e. Lakshmi Machine Works Ltd., Coimbatore, Schlaforest (Germany), Vijay Savio (Italy), Trumac Engineering Co. P. Ltd. and Veejay Lakshmi Engineering Works Ltd. The Company has OE, Spinning Capacity of 2464 rotors. Unit has 100% captive thermal power plant capacity of 31MW. World class quality yarn manufacturing capabilities begin with world -class in house yarn dyeing plant with the 100% capacity.

WEAVING UNIT: Best of international technology.. Equipped with latest SULZER P-7100, DORNIER Rapier HTVS8/s and New Air Jet (TOYTA) and Sudo Kama weaving machines with latest Electronic Jacquards 257 weaving machines. BENIENZER warping machine.

Capacity to produce 25 million meter fabrics per annum of synthetic and denim fabric.

PRODUCT OVERVIEW YARN:

Major part of the total yarn production consists of all varieties of P/V dyed yarns used in the manufacture of suiting and shirtings. In the fibre dyed yarn, the SIL is considered as one of the market. The quality and shade range offered by the company is unmatched as a result its production is always sold in advance. The company leaps orders of more than one month in hand. Offers the widest range of colours & shades of dyed yarns. Maintaining stringent international quality standards. SIL produces high quality cotton yarn mainly exported. SIL exports substantial quality of dyed yarns to Turkey , Belgium and other European markets.

FABRICS:

SIL primarily manufactures suiting and denim fabrics, for which yarn manufactured in-house forms the key raw material. Suitings are marketed under Sangam & Anmol brand names. Over the years, SIL has developed an extensive distribution network of 150 dealers. 30%-40% of the revenues are derived from the export market South Africa , Kenya , and the Middle East markets.

PROCESSING ACTIVITY :
Latest international technology. Equipped with latest KD/TMT Machine for permanent finish. Equipped with relax scouring machine. Equipped with Rotary press and Zero-Zero machine. Latest processing facilities for quality denim fabric.

FLOCK FABRIC :
Upholstery - Printed velour, Dyed velour, Scotchgard transfer print. Curtains- Thermal Curtain, 2 Pass Black Out, Transfer Print, Pattern Curtain, Jaquard Curtain. Dress Material - Cut Flock, Spenish feel, Magic feel, Super tafett, Semi dull tafetta, Corduroy.

BIBLIOGRAPHY
1. www.google.com 2. www.wikipedia.com 3. www.rswm.in 4. www.sangamgroup.com 5. Information from concerned companies.