Description
The words fabric and cloth are used in textile assembly trades (such as tailoring and dressmaking) as synonyms for textile. However, there are subtle differences in these terms in specialized usage.
ACKNOWLEDGEMENT
The feeling of gratitude automatically arises from the bottom of heart when we are helped by anyone. A small but timely help can prove to be achievement of an important milestone i.e. the completion of this project report.
I am thankful to K.S. School of Business Management for giving me such a nice opportunity to expand and widen my learnings. I am also thankful to the management of the Unicottex Fabrics for providing me such a nice platform where I got all the insights of production and marketing. The practical as well as theoretical knowledge which I got is immensely valuable.
EXECUTIVE SUMMARY
One important reason for selecting textile sector for this project is my personal interest and in future I want to start my own venture in this field. But in my view to start any venture in production one must have at least 5 years of experience in this area. I’ve been taking training in Unicottex Fabrics from last 2 years and this summer training has helped me in expanding my learning in the field of textiles. This summer training was indeed very helpful to me because whatever I have learned so far in this field is now written in terms of this project report. I have prepared this report in 2 parts: Production and Marketing. I have tried to do something new by doing project on production because I have seen that nobody has taken the topic of production for their summer internship reports. I have tried to include various topics of production like deciding factory location and its layout, purchase and inventory management, production process, quality and maintenance management, etc. I firmly believe that any person who is into production must have vast knowledge of these areas because if mismanaged it can lead to wastage of resources and increase in production cost. I have tried to cover how all the above mentioned practices are being followed by the Unicottex Fabrics. Another important task of any business is marketing. There is no meaning in making any superior product unless you have marketed it well. In the field of textiles one should have variety of products in its portfolio and should have competitive advantage over rivals so that it can price its product well. Another important aspect of marketing in this field is the superior distribution channel so that one can deliver the product on time. Earlier promotion was not considered to be the important part of this field but with the increased competition online marketing i.e. marketing through B2B marketplaces have emerged as an effective source of marketing for any textile company. I have tried to cover all the necessary aspects of production and marketing in this report which will be very helpful for me in future and for other students also who want to prepare their report on the topic of production.
INDIAN WEAVING INDUSTRY
Indian weaving industry has conventionally been one of the most promising sectors of huge employment. In fact, after agriculture, this industry is largest provider of work force. The abundance in the raw materials, the continuous supply of cheap work force is the contributing factors behind the success of the weaving industry of India. However, the liberalization of the international trade coupled with change in the reforms of domestic economy, have made affected the weaving industry of India negatively.
PRESENT SCENARIO
The manufacturing of the weaving products makes a remarkable contribution to the national GDP and even in the exports revenue. Over 38, 00,000 weaving industries have been built throughout India, and more than 15, 00,000 domestic weaving industries have been set up in the states of North and Eastern parts of India. On the other hand, the southern states also have their huge share of weaving industries, for example, the southern state of Andhra Pradesh houses some 3, 20,000 weaving industries. Most of these industries are situated in South India and North India. All these sectors are engaged in the production of unique varieties of weaving products. Both the weaving sectors of northern and southern India are engaged in the weaving production for the domestic market as well as international market. The weaving industry in India has self-depending mechanism that includes training the young weavers, abundance of resources and capacities, thereby, helping the industry not to be dependent on the Government. In addition, weaving is eco-friendly, and is aimed at the cutting back on the environmental impact.
FUTURE SCENARIO
It is estimated that the weaving industry in India will grow by 25% to over 40 million tons by the year 2010. The Indian weaving industry will maintain its growth throughout 2012. Apparel being the mostly used woven products is expected to expand its market in the international arena as well.
UNICOTTEX FABRICS: COMPANY PROFILE
Unicottex Fabrics (N.H. Group) has established itself as an eminent manufacturer and supplier of an appealing assortment of Cotton, PV & Other Fabrics. Our range includes Cotton Fabric, PV Fabrics, PC Fabrics, Shirting Fabrics and Handkerchief Fabrics. These products are offered in a wide variety of designs, sizes, patterns and colours in order to meet the diverse demands of the clients. The quality controllers of our team ensure that the raw material used in the manufacturing process of these fabrics is acquired from the established vendors of the market. Our robust infrastructure unit is equipped with latest equipment and machines, that facilities faster production of quality-assured products. We also render customization service to our clients in order to meet their specific requirements. Unicottex Fabrics has 4 plants all located in Rakhial, producing different kind of fabric.
Business Type Year of Establishment Produciton/Annum Annual Turnover Total Number of Employees
Manufacturer Supplier 1988 Approx 3 Million Meters INR 150 Million Approx 100 Approx
SWOT ANALYSIS OF UNICOTTEX FABRICS (YEAR 2011)
ORGANISATION CHART
FACTORY LOCATION
The factory of Unicottex Fabrics is located in Rakhial which is considered to be the idle place for the weaving industry because of the proximity of the suppliers and customers. From many years many weaving units are installed in Rakhial and vicinity area. For Unicottex Fabrics the reasons for selecting Rakhial for installing a new unit are as follows: ? ? ? ? ? ? ? Proximity to suppliers of raw material Proximity to customers Proximity to the textile process plants Proximity to the textile spear parts dealers Less transportation cost Easy availability of workers Presence of the textile industry in Rakhial
Factory Address: Tejendra Industrial Estate, Opp. Reliance’s Petrol Pump, Rakhial, Ahmedabad-380023.
FACTORY BUILDING
Unicottex Fabrics has a single storey factory building. It is idle practice in weaving industry to have single storey factory building because the machineries are quite heavy in nature and it is somewhat difficult to move the materials also in multiple storey building. We have flourished a top-of-the-line infrastructure unit that is spread over a vast area. This unit is installed with advanced machines and sophisticated technology that facilitates and faster production of quality-assured products. We have segmented this unit into various departments such as manufacturing, and warehousing & packaging. This enables us to carry out all the production processes simultaneously in a hassle-free manner. Manned by highly trained professionals, this well organized unit assists us in meeting the bulk orders with in stipulated time.
Reasons for selecting Single Storey Building
? Better support for heavy machines. ? Better and faster movement of material and output. ? Faster evacuation in case of fire. ? From the view point of the safety of the workers it is always advisable. ? No need of vertical transportation of raw materials and product.
FACTORY LAYOUT
PURCHASE MANAGEMENT
Purchasing of raw materials and supplies is an important task for manufacturing firm. General Manager is responsible for the task of purchasing at Unicottex Fabrics. The main task for the General Manager in purchasing is the procurement of yarns as it is the main raw material. Purchasing of yarns is comprised of several steps which are as follows: 1. Once the order is received from customers the complete specification is given to the buyer about the product quality and yarns to be used (quality, count, and the mill of the yarn supplier). 2. Once it is approved by the buyer prices are obtained from different agents for the required yarn quality and quantity along with the date of delivery. 3. Quotations are received from different agents regarding the required yarn along with the terms and conditions related with the purchase. 4. Evaluation of the quotation is done by the General Manager. 5. The order for the yarn is placed with the agent whosoever offers the best price and flexible terms and conditions for the required yarn.
Note: The agent of the yarn is responsible if the yarn received is not as per the specifications given by Unicottex Fabrics. Unicottex Fabrics may not accept the goods in such case. For purchasing of yarns Unicottex Fabrics always rely on multiple sources as it provides following advantages to the firm: I. II. III. Obtaining the best possible prices. Bargaining power of the firm increases. It provides more flexible purchasing.
Factors considered by Unicottex Fabrics while selecting the source
I. II. III. IV. V. VI. VII. VIII. Reliability of the supplier and the agent. Ability to meet the order on time. After sale services given by the agent. Past Experience. Location of the supplier. Buying convenience. Financial position of the supplier. Discount offered.
INVENTORY MANAGEMENT
The term inventory includes raw material, work-in-process, finished goods and stores and spares. Inventory management involves administration, policies and procedures to reduce inventory cost.
The categorisation of inventory at Unicottex Fabrics is done in 3 parts:
PRODUCTION INVENTORY: It includes yarn, the most essential product to produce any fabric. MRO INVENTORIES: It includes oil, spare parts of the machine, etc. FINISHED GOODS INVENTORIES: Grey Fabric
Inventory Required for Production
Inventory Yarn MRO Inventory % of Total Inventory 90 10
RAW MATERIAL: YARN
Policy followed in management and control of yarn: Just in Time
Yarn is a basic raw material required to produce any fabric. Its requirement is actually dependent on the quality of fabric to be made. Unicottex Fabrics follows the policy of Just in Time (JIT) to maintain the inventory of yarn. Apart from that yarn prices are highly fluctuating in nature so it is actually advisable to acquire the yarn whenever required to gain maximum advantage of price fluctuations.
There are several advantages of following JIT policy for Unicottex Fabrics. They are as follows: Reduction in working capital investment: Yarn constitute about more than 90% of
inventory of any fabric producer. The yarn prices for the products of Unicottex Fabrics are quite high, so by following JIT technique the company can reduce its investment in yarn.
Reduction in storage costs: Yarn is the most essential and important raw material and it is
required to be stored carefully. Hence by following JIT technique the company is actually able to reduce its storage costs.
It leads to better quality control of the yarn. It also leads to reduction in wastages and better utilisation of yarns.
Note: Unicottex Fabrics is able to stand firm by following JIT technique in the recent price fluctuations of yarn, which are proven very adverse for the other companies.
MRO INVENTORIES
MRO inventory includes inventory of oil and spare parts of the machine. It is required to keep the machine up to date and for smooth and damage less production of the fabric.
Inventory of Oil
Unicottex Fabrics places blanket orders for purchasing oil. It is generally given for one financial year. The blanket order for the current financial year is placed with Ankur Oils. Unicottex Fabrics maintains only the required inventory of oil and rest is kept with the seller. Generally the similar policy is followed by other firms also in the industry since it holds very less part of total inventory.
Inventory of Spare Parts
It includes machine parts like shuttles, belts, frames, chains, etc. Unicottex Fabrics has given contract to J.R. Patel and Co. for supply of spare parts for the current financial year. In this case parts are supplied by J.R.Patel and Co. whenever it is needed by Unicottex Fabrics and the supplier is responsible for its complete replacement if the part is damaged. Very minimal inventory of spare parts is maintained on the factory, hence it reduces the storage cost and its maintenance cost.
FINISHED GOODS INVENTORY
The only finished goods inventory for Unicottex Fabrics is the Grey Farbic. Unicottex Fabrics follows the policy of supplying grey fabric once the output level for one order placed by the buyer reaches 5000 Meters. The arrangement of managing finished goods inventory is done such that the inventory of grey fabric doesn’t exceed 15,000 Meters at any point of time.
Note: However early/delayed deliveries can be done at prior request of the buyer.
Advantages of following above policy:
The prime advantage is the reduction in the storage cost of the grey fabric. Another advantage is the reduction in the transportation cost per meter of the grey fabric.
STORES MANAGEMENT
Meaning: Storage is the function of receiving, storing and issuing materials. Stores ensure
ready accessibility of major materials there-by efficient service to users. Minimisation of stores cost, and continuous supply is the prime function of the stores. At Unicottex Fabrics store is used to keep the inventory of yarns, grey fabrics, spare parts and oils. Unicottex Fabrics has allocated around 1500 square feet area for stores. It follows fixed location policy to store different materials for easy identification and speedy movement of the inventories.
STORES LAYOUT
Snapshot of Store Room
STOCK VERIFICATION
Store Keeper is responsible for the task of stock verification. FIFO method is used in determining the value of stock.
THE PRODUCTION PROCESS:WEAVING
The production process of grey fabric is not difficult as it includes only one raw material that is yarn. However it is somewhat complex because it requires calculations. Here I am not going to talk about those lengthy calculations, rather I will draw attention on how actually the fabric is made in some deep details about the raw materials used and the process to produce the grey fabric. The process of weaving can be determined as follows:
RAW MATERIAL: YARN
The basic and the most important raw material required for manufacturing grey fabric is yarn. Now let’s understand about the yarn and its different kinds in detail.
Description: Yarn is a long continuous length of interlocked fibres which is used in textile to
produce fabric. It is one kind of thread. It is one kind of filament, fibre or thread which is used to made cloth. The word originally referred only to woven fabrics but now includes knitted, bonded, felted, and tufted fabrics as well. Yarn is generally made from raw cotton. However now a days it is also made from nylon, polyester, viscose, wool, etc. It is generally denoted by count. Higher the count thinner is the thread and lower the count thicker is the thread.
Note: Cotton yarns are denoted by Ne, while Texturized yarns are denoted by Denier.
Type of Yarns
Single Yarn
Single, or one-ply, yarns are single strands composed of fibres held together by at least a small amount of twist; or of filaments grouped together either with or without twist; or of narrow strips of material; or of single man-made filaments extruded in sufficient thickness for use alone as yarn (monofilaments).
Twisted Yarn
Single yarns of the spun type, composed of many short fibres, require twist to hold them together and may be made with either S-twist or Z-twist. Single yarns are used to make the greatest variety of fabrics. This kind of yarn is generally used in premium shirting fabric. 2/60 count is the most common count in producing premium shirting.
Ply Yarn
Ply, plied, or folded, yarns are composed of two or more single yarns twisted together. Twoply yarn, for example, is composed of two single strands; three-ply yarn is composed of three single strands. In making ply yarns from spun strands, the individual strands are usually each twisted in one direction and are then combined and twisted in the opposite direction. When both the single strands and the final ply yarns are twisted in the same direction, the fibre is firmer, producing harder texture and reducing flexibility. Ply yarns provide strength for heavy industrial fabrics and are also used for delicate-looking sheer fabrics.
Novelty Yarns
Novelty yarns include a wide variety of yarns made with such special effects as slubs, produced by intentionally including small lumps in the yarn structure, and man-made yarns with varying thickness introduced during production. Natural fibres, including some linens, wools to be woven into tweed, and the uneven filaments of some types of silk cloth are allowed to retain their normal irregularities, producing the characteristic uneven surface of the finished fabric. Man-made fibres, which can be modified during production, are especially adaptable for special effects such as crimping and texturizing.
Filament Yarn
Filament yarn consists of filament fibres (very long continuous fibres) either twisted together or only grouped together. Thicker monofilaments are typically used for industrial purposes rather than fabric production or decoration. Silk is a natural filament, and synthetic filament yarns are used to produce silk-like effects.
Texturized Yarn
Texturized yarns are made by a process of air texturizing, which combines multiple filament yarns into a yarn with some of the characteristics of spun yarns.
WARP AND WEFT YARNS
In weaving, the warp, or lengthwise, yarns are subjected to greater stress and are usually stronger, smoother, and more even and have tighter twist than the weft, or crosswise, yarns. A sizing (stiffening) material such as starch may be applied to warp yarns, increasing their strength to withstand the stresses of fabric construction operations. Weft yarns, subjected to little stress during weaving, may be quite fragile.
YARNS USED BY UNICOTTEX FABRICS
COTTON YARN: Made from raw cotton. Unicottex Fabrics used carded and combed cotton
yarns which are bought from well known mills of India like Maharaja Pali Mills, DCM Mills, Nahar Spinning Mills, Vardhman, etc. through their appointed agents. 40 Ne, 50 Ne, 32 Ne, 30 Ne, 2/60 Ne are the regular used cotton yarns by the Unicottex Fabrics.
POLYESTER COTTON (PC) YARN: It is a blend of polyester and cotton.
Blends Available: 48:52 (48% Polyester and 52% Cotton)
65:35 (65% Polyester and 35% Cotton) 70:30 (70% Polyester and 30% Cotton) 85:15 (85% Polyester and 15% Cotton) 65:35 PC blend is regularly used by Unicottex Fabrics and it is bought from Asarva Mills (Ahmedabad) and Chorus Mills (Vankaner) through their appointed agents.
POLYESTER VISCOSE (PV) YARN: It is an organic yarn. It is a blend of polyester and
viscose.
Blends Available: 48:52 (48% Polyester and 52% Viscose)
65:35 (65% Polyester and 35% Viscose) 70:30 (70% Polyester and 30% Viscose) 80:20 (85% Polyester and 15% Viscose) 65:35 PV blend is regularly used blend by Unicottex Fabrics and it is bought from Sounderaja Mills, Rajasthan Textile Mills, Sangam Mills and Maharaja Pali Mills from their appointed agents.
Note: The approximate yarn usage of Unicottex Fabrics for 1 month is around 10 tons.
WARPING
Warping is the processing of creating the base yarn that runs top to bottom on woven cloth. Through warping the warping yarn is inserted into a warping beam which is finally attached at the back of the weaving loom. The primary objective of the warping process is to provide a continuous length of yarn from individual wound yarn packages, in sheet form to a beam for the succeeding process. When utilizing any technique in the warping process it is important to minimize end breaks, keep a constant and uniform tension on the yarns, keep a constant yarn speed, and insure quick response braking of the warper. These factors play a large role in the quality of the warp yarns, which in turn influences the runability of that warp yarn in the succeeding process.
SIZING
Sizing of the warp yarn is essential to reduce breakage of the yarn and thus production stops on the weaving machine. On the weaving machine, the warp yarns are subjected to several types of actions i.e. cyclic strain, flexing, abrasion at various loom parts and inter yarn friction. With sizing the strength - abrasion resistance - of the yarn will improve and the hairiness of yarn will decrease. The degree of improvement of strength depends on adhesion force between fiber and size, size penetration as well as encapsulation of yarn. Different types of water soluble polymers called textile sizing agents/chemicals suchasmodified starch, polyvinylalcohol (PVA), carboxymethyl cellulose (CMC), acrylates are used to protect the yarn. Also waxis added to reduce the abrasiveness of the warp yarns. The type of yarn material e.g. cotton, polyester, linen,... the thickness of the yarn, type of weaving machinery will determine the sizing recipe. The sizing liquor is applied on warp yarn with a warp sizing machine. After the weaving process the fabric is desized (washed).
WINDING
Yarn cannot be inserted directly through cones. Yarn is inserted into bobbins. This process is called winding. And these bobbins are inserted into shuttles for the purpose of weft insertion in the weaving process.
WEAVING PROCESS
Woven cloth is normally much longer in one direction than the other. The lengthwise threads are called the warp, and the other threads, which are combined with the warp and lie widthwise, are called the weft. An individual thread from the warp, of indefinite length, is called an end; each individual length of weft, extending from one edge of the cloth to the other, is called a pick, or shot. Consecutive picks are usually consecutive lengths of one piece of weft yarn that is repeatedly folded back on itself. In all methods of weaving cloth (except the rudimentary form of darning), before a length of weft is inserted in the warp, the warp is separated, over a short length extending from the cloth already formed, into two sheets. The process is called shedding and the space between the sheets the shed. A pick of weft is then laid between the two sheets of warp, in the operation known as picking. A new shed is then formed in accordance with the desired weave structure, with some or all of the ends in each sheet moving over to the position previously occupied by the other sheet. In this way the weft is clasped between two layers of warp. Since it is not possible to lay the weft close to the junction of the warp and the cloth already woven, a further operation called beating in, or beating up, is necessary to push the pick to the desired distance away from the last one inserted previously. Although beating in usually takes place while the shed is changing, it is normally completed before the new shed is fully formed.
The sequence of primary operations in one weaving cycle is thus shedding, picking, and beating in. At the end of the cycle the geometrical relation of the pick to the warp is the same as it would have been if the pick had been threaded through the spaces between alternate ends, first from one side of the cloth and then from the other, as in darning. This is the reason the weaving process is considered an interlacing method.
KIND OF WEAVES AT UNICOTTEX FABRICS
Plain Weave
1 Up 1 Down Plain Weave Plain weave is the simplest and most common of all weaves, requires only two harnessses and has two warp and weft yarns in each weave unit. To produce it, the warp yarns are held parallel under tension while a crosswise weft yarn is shot over and under alternate warps across the width of the web. The weave unit is completed at the end of the second row, when the weft has been inserted over and under the opposite set of warps, thus locking the previous weft in place. Fabric length is increased with the insertion of each succeeding weft yarn. When warp and weft yarns are approximately equal in size and quantity, the finished fabric is balanced and potentially stronger than cloth made of the same kind and number of warp and weft yarns in any other basic weave. At Unicottex Fabrics around 70-80% fabric is made using plain weave.
Note: In plain weave ends per inch is equal to the picks per inch. Around 80% of the total fabric in the world is made in plain weave.
Twill Weave
3/1 Twill (3 up, 1 down)
Left to Right Twill
Twill weave is distinguished by diagonal lines. The simplest twill is that created by the weft crossing over two warp yarns, then under one, the sequence being repeated in each succeeding shot (pick), but stepped over, one warp either to the left or right. Twills with more warps than wefts floating on the fabric’s face are called warp faced; those with wefts predominating, weft faced. The angle of the twill can also vary.
Commonly Used Twills in Weaving Twill
2:1 3:1 2:2 (Balanced) 3:3 (Balanced)
Interpretaion
2 up, 1 down 3 up, 1 down 2 up, 2 down 3 up, 3 down
Note: Twill weave is commonly used in producing denim fabric. At Unicottex Fabrics twill weave is used in manufacturing shirting fabric.
Satin Weave
Although satin-weave drafts superficially resemble those of twills, satin weave does not have the regular step in each successive weft that is characteristic of twills. Thus, there is no strong diagonal line, and the fabric is smooth faced, with an unbroken surface made up of long floating warp yarns. A true satin must have at least five warp and weft yarns in each complete weave repeat and thus requires at least five harnesses. Most satin fabrics are made of smooth, lightly twisted yarns that heighten the effect of light unbroken by visible crosswise bindings. The limited number of interlacings allows the weaver to use a proportionately large number of warp yarns and thus produce a heavy textured cloth that can be arranged in smooth, shadowed folds. Satins, having long floats, are susceptible to the wear caused by rubbing and snagging and are, therefore, generally regarded as luxury fabrics. Satin weaves are generally used in premium shirtings and high quality bed sheets. Unicottex Fabrics also uses satin weaves in its 47” cotton satin.
PRODUCTION TECHNOLOGY
Unicottex Fabrics is a manufacturer of premium grey and shirting fabrics. It manufactures all categories of grey fabrics be it Cotton, PC or PV. For the purpose of best weaving they have it is equipped with 24 high speed Ruti-B looms which are considered to be the best for premium weaving solutions. The looms have the capacity to produce 50000 Meters of grey fabrics every month. The technical specifications of the Ruti-B looms are as follows.
Ruti-B
Technical Specifications of Ruti-B Particulars
Manufacturer Speed Reed Width (in Inch) Weft Insertion Motor Weaving Solutions
Specifications
Sulzer (Switzerland) in association with Mafatlal Mills, Ahmedabad 220 RPM 48” Upto 200 picks/minute 1.5 HP Plain, Twill, Satin
Snapshots of Ruti-B
WARP BEAM
THE USE OF CAD @ UNICOTTEX FABRICS
The use of CAD in textile industry is increasing day by day. Unicottex fabrics realises its importance and uses CAD softwares like DB Weave and Weave Point to design its shirting fabrics. The use of CAD gives advantages in many ways like, it helps in better design of fabrics, improved production, less wastages and reduced manufacturing and design cost. Human errors in designing is also taken care of in CAD systems.
Screenshot of DB Weave
PEOPLE
People are the most valuable asset of any organisation, and at Unicottex Fabrics also we understand the value of the people that are connected with the company. Unicottex Fabrics has certain criteria for the recruitment of workers and it always believes in maintaining long term relationship with its workers. It also offers training programmes to its workers for increasing their effectiveness.
Employee Structure
Employee Strength Workers associated with the production Jobbers Production in Charge Helper Mending Folding 20 6 + 3 Relievers 2 1 4 1 1
Note: Labours associated with shedding of beams are not part of employee structure of Unicottex Fabrics.
Workers directly associated with production
Responisibilities
? To ensure continuous and damage less production. ? Communication and co operation with the jobber.
Criteria of Recruitment
? Experience of minimum 5 years in weaving department. ? Ability to solve minor technical problems. ? Flexibility (can be asked to work in any shift)
Jobber
Responisibilities:
? Maintenance of machinery. ? Co-operate with workers. ? To ensure damage less and continuous production.
Criteria of Recruitment:
? Minimum 10 years of experience as jobber in weaving department of Ruti B machines. ? Flexibility. ? Communication skills (Hindi, Tamil, Gujarati) ? Must have up to date technical knowledge of Ruti B machines.
Production in Charge
Responsibilities
? Responsible to meet the production as per the standard. ? Responsible for recruitment of the workers for production and of jobbers. ? Responsible to ensure that all the shifts of production are working as per the schedule. ? Responsible to design reward policies for the workers directly associated with production. ? Communication and co-operation with the jobbers, workers and the management.
Criteria of Recruitment
? Minimum 10 years of experience as production in charge in weaving department. ? Communication skills (Hindi, English, Gujarati, Tamil) ? Must have technical knowledge of all aspects of weaving machineries.
WAGES AND SALARIES
Workers directly associated with production
Wage Pay Policy Wage for 1 worker/Shift (12 Hours) (Working of 26 days) Bonus Reward Policy Fix Pay System + Reward Rs. 250 8.33% of total annual wages Rs. 20/Day additional if a worker is present on all working days. Workers Insurance Scheme by ATIRA Workmen Compensation Insurance by United India Insurance Company Training programmes offered by ATIRA
Benefits
Training
Note: Relievers are also paid same amount, however they are not entitled for any rewards.
Wages of Helper, Mender and Folder
Helper Mender Folder Wages Bonus Rs. 100/ Day Rs. 0.12/Meter Rs. 75/ Loom/Month 8.33% of total annual wages
Jobbers
Wage Pay Policy Wages paid to jobber/day Bonus Benefits Workmen Compensation Insurance by United India Insurance Company Fix Pay System Rs. 475 for 12 hour shift 8.33% of total annual wages Workers Insurance Scheme by ATIRA
Production in Charge
Salary Policy Salary/Month Bonus Benefits Workmen Compensation Insurance by United India Insurance Company Is entitled for training and development programme offered by ATIRA Fix Pay System Rs. 18000 10% of total annual salary Workers Insurance Scheme by ATIRA
Training
QUALITY MANAGEMENT @ UNICOTTEX FABRICS
Quality: Quality may be defined as the sum total of features of a product which influence its
ability to satisfy a given demand.
Dimensions of the product quality
? ? ? ? ? ? ? Performance of the product Features of the product Reliability of the product Serviceability of the product Appearance of the product Customer Service/After sales support Safety
Quality Control: Quality control is an effective system for integrating the quality
development, quality maintenance and quality improvement efforts of the various groups in an organisation so as to enable production and service at the most economical levels which allow for full customer satisfaction. Quality control helps to minimise the costs of inspection and rejection. At Unicottex Fabrics Quality Control is given foremost priority and the task is performed by everyone in the organisation be it top management, middle management or bottom level management. Everyone is involved in controlling the quality of the product. At Unicottex Fabrics Quality Control is done in different stages and by different departments. Quality Control in designing of the product and purchasing of the raw material is done by the top management, while care of quality while manufacturing is taken by the production in charge and the jobbers. After sales support and communication with buyers is done by the appointed agents. Now let’s understand how the quality control work is done by different departments:
QUALITY CONTROL IN DESIGNING OF THE GREY FABRIC & PURCHASE OF YARNS
This task is performed by the General Manager. There are several steps involved in this task which are as follows: I. First when the order is received from the buyer, clear communication is done with him regarding the specifications of the product, yarns to be used, density of the yarns, the use of the grey fabric etc. Once the product specifications are received grey fabric is designed on computer. Fabric designing requires lengthy calculations like calculations of set length, fabric width, weight of the fabric, etc. For this purpose softwares are used to arrive at accurate designing of the product. Once the fabric is designed and yarn requirement is calculated, yarn is ordered through our appointed agents. It is generally bought from finest mills of India. The final fabric quality is ultimately depended on the yarns used. For quality assurance to customer Unicottex Fabrics only uses yarns of mills and does not purchase yarns from local suppliers. Further when the yarn is received from the supplier it is checked by the production in charge and the general manager to ensure that it is as per the specifications. Once the complete designing is done a printed sheet regarding all details of the product to be manufactured is handed over to the production department.
II.
III.
IV. V.
QUALITY CONTROL IN MANUFACTURING OF THE GREY FABRIC
This task is performed by the production in charge along with the jobbers and the workers. It includes following tasks: I. II. III. Before installing a new cloth beam on the machine, machine is properly inspected, cleaned and lubricated so that the new cloth beam runs smoothly. Parts of the machine like shuttles, reed frames, and chains are up to date and are not defective. For smoother production of the grey fabrics air coolers are installed in the plant which maintains required humidity in the plant. Without required humidity the fabric looks dull and rough. Once the production is started, daily samples of the fabric are taken to check the width of the fabric is as per the specifications. It is one of the important tasks because width of the fabric changes in different processes. Note: If the fabric width is not as per the specifications or there are any damages in warp then reshedding process is done. Once the grey fabric is produced it goes to mending department where all the excess threads of the fabric are removed and then it goes to folding department for folding. For accurate calculation of the fabric folded electronic devices are attached with the folding machine. Once the fabric is folded it is stored in storage department. For the quality assurance of the final grey fabric storage department is kept clean and neat so as to avoid any damage to the fabric.
IV.
V.
VI.
QUALITY CONTROL AFTER DELIVERY OF THE GREY FABRIC
Once the grey fabric is delivered to the buyer our appointed agents comes in contact with the buyers to ensure that product delivered is as per the buyer’s specifications. Further if the buyer wants any changes in future deliveries of the product it can also be done through communication with our agents. Unicottex Fabrics believes in customer first policy. It encourages complaints of buyer so as to avoid the same mistake in future. Customer complaints regarding any feature of the product always encourage us to concentrate more on quality.
BENEFITS OF QUALITY CONTROL
I. II. III. IV. V. VI. VII. VIII. Reduced wastage of yarn. Reduced cost of labour per meter of fabric. Improved fabric quality. Reduction in inspection costs. Increased production. Higher operating efficiency due to reduced wastages and damages. Better utilisation of resources. Better customer satisfaction.
MAINTENANCE MANAGEMENT
Maintenance is the function of the production department and it is headed by the production in charge in Unicottex Fabrics. The prime task of the maintenance team is to keep the plant and the machineries in sound condition. The following tasks are performed by the maintenance team at Unicottex Fabrics: I. II. III. IV. V. Maintenance of the plant and the machineries. Inspection of the machines and lubrication. Waste disposal. Humidity and temperature control in the plant. Plant protection.
Maintenance Policy Planned Maintenance
Unicottex Fabrics follows policy of planned maintenance. Maintenance of plant and machinery is scheduled on every 15th day during staggering. The entire plant is shut down on that day because of staggering and the maintenance team does the work on that day.
Routine Maintenance
Apart from planned maintenance routine maintenance is also done during the work. It includes oiling and lubrication of the machine, cleaning, etc.
PRODUCT & PRICE
PRODUCT PORTFOLIO
We are a reliable manufacturer and supplier of an enticing collection of Cotton, PV & Other Fabric. Our fabrics find extensive application in various sectors of the textile industry. These fabrics are well-known in the market for their unique designs, exotic colors, colorfastness, skin-friendliness and shrink-resistance. Considering the diverse demands of the clients, these fabrics are made available in varied sizes, colors, designs and patterns. Our range includes following products:
? ? ? ? ?
Cotton Fabric PV Fabrics PC Fabrics Shirting Fabrics Handkerchief Fabrics
PRICING
Unicottex Fabrics follows mark up pricing policy. In which a certain percentage of markup is added to the total cost of the fabric. In all the products manufactured, Unicottex Fabrics follows the same policy of pricing. Different factors like competition, demand of the product, quality of the product are considered while pricing the product. The percentage of mark up varies as per the different situations, but the pricing policy remains the same.
COTTON
We are instrumental in offering a qualitative range of cotton fabrics to our esteemed clients. These fabrics are widely used for designing various garments and dresses. Our fabrics are offered in a wide variety of density, width and weaving style to meet the diverse demands of the clients.
Density Yarn Count Width Techniques Style Use Price/Meter
120*72 40*40 (Cotton) 47” Woven Satin Garment, Home Textile Rs. 35 (Subject to change)
Density Yarn Count Width Techniques Style Use Price/Meter
128*72 2/60*2/60 (Cotton) 47” Woven Plain Shirting Rs. 60 (Subject to change)
POLYESTER COTTON FABRIC
We are engaged in offering a sophisticated range of PC fabrics to our prestigious clients. Our range caters to the requirements of various industries. PC fabrics offered by us are manufactured employing high quality raw materials and advanced production techniques. It is used for multi purposes like printed fabrics, ladies wear, men’s apparel, etc.
Density Yarn Count Blend Width Techniques Style Use Price/Meter
96*72 45*45 PC 65:35 47” Woven Plain Shirting, Home Textiles Rs. 32 (Subject to change)
Density Yarn Count Blend Width Techniques Style Use Price/Meter
110*76 45*45 PC 65:35 47” Woven Plain Shirting, Home Textiles Rs. 34 (Subject to change)
Density Yarn Count Blend Width Techniques Style Use Price/Meter
88*64 45*45 PC 65:35 47” Woven Plain Shirting, Home Textiles Rs. 29 (Subject to change)
POLYESTER VISCOSE FABRIC
Our polyester viscose fabric is manufactured by using high quality of PV yarn acquired from popular mills of India. These fabrics are well-known for their attributes such as shrink-resistance, durability, colour fastness. These fabrics are fully customised as per customer’s specification in terms of density, width of the fabric and weaving pattern. These fabrics are highly demanded for its softness. It is generally used in ladies dress materials, shirting and fashionable scarves.
Density Yarn Count Blend Width Techniques Style Use Price/Meter
96*92 (Slub) 40*40 PV 48:52 38” Woven Plain Shirting Rs. 33 (Subject to change)
Density Yarn Count Blend Width Techniques Style Use Price/Meter
84*80 40*40 PV 65:35 38”/60” Woven Plain Shirting, Dress Materials Rs. 28 (Subject to change)
SHIRTING FABRIC
We present forward to our esteemed clients a steadfast range of shirting fabrics at market leading prices. These fabrics are made accessible in yarn dyed and printed type. We have tie up with best manufacturers of the shirting grey fabric to provide unmatched quality of shirting fabric. We are able to supply different varieties of shirting fabrics like plain, check, cotluk check, filafil, etc. This fabric is available in the width of 58”.
CHECK SHIRTING FABRIC
Density Yarn Count Width Techniques Style Use Price/Meter
76*72 2/60*2/60 100% Combed Cotton 57-58” Woven Plain Men’s Shirting Rs.90/ Meter
SLUB CHECK FABRIC
Density Yarn Count Width Techniques Style Use Price/Meter
80*72 40*40 Combed Cotton 57-58” Woven Plain Men’s Shirting Rs.95/ Meter
COTLUK FILAFIL CHECK FABRIC
Density Yarn Count Width Techniques Style Use Price/Meter
80*72 180*180 Denier 57-58” Woven Plain Men’s Shirting Rs.95/ Meter
HANDKERCHIEF FABRIC
We have for our prestigious clients a comprehensive gamut of handkerchief Fabrics. These fabrics are manufactured using 100% cotton, which is acquired from the trusted vendors of the market. In order to cater to the specific requirements of our clients, we customize these products on following parameters: ? ? ? Designs Colours Patterns
The price of the handkerchiefs is completely dependent on its pattern and quality so it is not disclosed here. However the same pricing policy i.e. Markup pricing policy is also followed here.
PLACE
DISTRIBUTION CHANNEL
A distribution channel performs the work of mooving the goods from producers to consumers. Unicottex Fabrics follows the policy of Selective Distribution. Unicottex Fabrics does not have any shop or outlet to distribute its products. Products are generally sold and distributed either directly or through appointed agents. Thus it operates through both direct and indirect chains of distribution.
DIRECT MARKETING CHANNEL
ONE LEVEL CHANNEL
Total Agents: 4 Commission Paid: 0.5% of the sales value
ROLES AND RESPONSIBILITIES OF APPOINTED AGENTS
? ? ? ? To carry out timely delivery. To execute trade promotion tools. To communicate terms and conditions related with the goods to the buyer. To maintain relationship with company and the buyers.
MARKETING FLOWS IN DISTRIBUTION CHANNEL
PHYSICAL FLOW (FORWARD FLOW)
TITLE FLOW (FORWARD FLOW)
Agents (Does not take title of the goods)
Unicottex Fabrics (Manufacturer)
Buyer/Customer
PAYMENT FLOW (BACKWARD)
INFORMATION FLOW (BOTH SIDED)
RISK FLOW
PROMOTION
Promotion is an integral part of any business. For an industry like textile promotion is certainly limited to trade discount and cash discount. Cash discount has become essential for the textile industry to generate speedy payments because credit period is quite long in this industry. However for weaving industry credit period on an average is of about 30 days.
Promotion Policy at Unicottex Fabrics
Credit Period Offered: 15-30 Days after the delivery of the goods.
Trade Discount: No trade discount is given by the firm except the order is above 15000
Meters. If the order is above 15000 meters 1% trade discount is given to the buyer.
Cash Discount: Unicottex Fabrics follows cash discount policy of 2/10 net 30 terms.
Note: Special offers and discounted price is offered to buyers in case of surplus stock.
ONLINE MARKETING
In this era of internet and technology online marketing has made its distinct place now. Earlier online marketing was generally done for consumer goods, travel and tourism products, etc. But now a day’s industrial products are also marketed through B2B marketplace. Unicottex Fabrics has also understood the importance of online marketing and advertising and has collaborated with Indiamart Intermesh Ltd to market its products. Unicottex Fabrics has designed its online catalogue with www.indiamart.com and buyers from 196 countries can inquire about the products of Unicottex Fabrics.
Snapshot of webpage of Unicottex Fabrics
Product Showcase The online catalogue of Unicottex Fabrics is designed keeping in mind that potential buyers can easily navigate through the webpage and can inquire about the products of the company easily by making a free call, sending free sms or by sending an email. The products showcase facility is also available on the webpage of Unicottex Fabrics so that buyers can easily navigate through different products of the company and can have a closer look at it. Apart from it Unicottex Fabrics also gives banner ads in the category of Fabric and Textiles on www.indiamart.com so that any potential buyer can easily come on the webpage of Unicottex Fabrics.
Advantages of Online Marketing to Unicottex Fabrics
I. II. III. IV. V. Internet marketing is inexpensive compared to the other Medias of advertising. The cost of reaching the target audience is low. More widely reach of target audience. Multimedia effects like videos, images, banners can be used. Customers can inquire easily without incurring any cost. Export order queries from more than 196 countries.
LEARNINGS @ UNICOTTEX FABRICS
Before taking the decision of doing MBA I was pretty sure that I will start my own venture and do something related to our family business. Since the completion of my graduation I’ve been going to Unicottex Fabrics and learning new thing and dimensions of textile industry. During this so called Summer Internship training I enhanced my learning in the textile industry. I learned new insights in production and marketing. Production being the toughest for any manufacturing industry an entrepreneur starting a venture in production must know technical aspects. In Unicottex Fabrics I’ve learned many things in past 2 years and would learn new things before I start my new venture soon. I am very thankful to the Team Unicottex Fabrics for providing me such an important platform of learning entrepreneurship.
BIBLIOGRAPHY
Productions and Operations Management by K.Aswathappa and K. Shridhara Bhat Marketing Management by Philip Kotler
WEBOGRAPHY
www.google.com www.wikipedia.org www.britannica.com
doc_542834150.pdf
The words fabric and cloth are used in textile assembly trades (such as tailoring and dressmaking) as synonyms for textile. However, there are subtle differences in these terms in specialized usage.
ACKNOWLEDGEMENT
The feeling of gratitude automatically arises from the bottom of heart when we are helped by anyone. A small but timely help can prove to be achievement of an important milestone i.e. the completion of this project report.
I am thankful to K.S. School of Business Management for giving me such a nice opportunity to expand and widen my learnings. I am also thankful to the management of the Unicottex Fabrics for providing me such a nice platform where I got all the insights of production and marketing. The practical as well as theoretical knowledge which I got is immensely valuable.
EXECUTIVE SUMMARY
One important reason for selecting textile sector for this project is my personal interest and in future I want to start my own venture in this field. But in my view to start any venture in production one must have at least 5 years of experience in this area. I’ve been taking training in Unicottex Fabrics from last 2 years and this summer training has helped me in expanding my learning in the field of textiles. This summer training was indeed very helpful to me because whatever I have learned so far in this field is now written in terms of this project report. I have prepared this report in 2 parts: Production and Marketing. I have tried to do something new by doing project on production because I have seen that nobody has taken the topic of production for their summer internship reports. I have tried to include various topics of production like deciding factory location and its layout, purchase and inventory management, production process, quality and maintenance management, etc. I firmly believe that any person who is into production must have vast knowledge of these areas because if mismanaged it can lead to wastage of resources and increase in production cost. I have tried to cover how all the above mentioned practices are being followed by the Unicottex Fabrics. Another important task of any business is marketing. There is no meaning in making any superior product unless you have marketed it well. In the field of textiles one should have variety of products in its portfolio and should have competitive advantage over rivals so that it can price its product well. Another important aspect of marketing in this field is the superior distribution channel so that one can deliver the product on time. Earlier promotion was not considered to be the important part of this field but with the increased competition online marketing i.e. marketing through B2B marketplaces have emerged as an effective source of marketing for any textile company. I have tried to cover all the necessary aspects of production and marketing in this report which will be very helpful for me in future and for other students also who want to prepare their report on the topic of production.
INDIAN WEAVING INDUSTRY
Indian weaving industry has conventionally been one of the most promising sectors of huge employment. In fact, after agriculture, this industry is largest provider of work force. The abundance in the raw materials, the continuous supply of cheap work force is the contributing factors behind the success of the weaving industry of India. However, the liberalization of the international trade coupled with change in the reforms of domestic economy, have made affected the weaving industry of India negatively.
PRESENT SCENARIO
The manufacturing of the weaving products makes a remarkable contribution to the national GDP and even in the exports revenue. Over 38, 00,000 weaving industries have been built throughout India, and more than 15, 00,000 domestic weaving industries have been set up in the states of North and Eastern parts of India. On the other hand, the southern states also have their huge share of weaving industries, for example, the southern state of Andhra Pradesh houses some 3, 20,000 weaving industries. Most of these industries are situated in South India and North India. All these sectors are engaged in the production of unique varieties of weaving products. Both the weaving sectors of northern and southern India are engaged in the weaving production for the domestic market as well as international market. The weaving industry in India has self-depending mechanism that includes training the young weavers, abundance of resources and capacities, thereby, helping the industry not to be dependent on the Government. In addition, weaving is eco-friendly, and is aimed at the cutting back on the environmental impact.
FUTURE SCENARIO
It is estimated that the weaving industry in India will grow by 25% to over 40 million tons by the year 2010. The Indian weaving industry will maintain its growth throughout 2012. Apparel being the mostly used woven products is expected to expand its market in the international arena as well.
UNICOTTEX FABRICS: COMPANY PROFILE
Unicottex Fabrics (N.H. Group) has established itself as an eminent manufacturer and supplier of an appealing assortment of Cotton, PV & Other Fabrics. Our range includes Cotton Fabric, PV Fabrics, PC Fabrics, Shirting Fabrics and Handkerchief Fabrics. These products are offered in a wide variety of designs, sizes, patterns and colours in order to meet the diverse demands of the clients. The quality controllers of our team ensure that the raw material used in the manufacturing process of these fabrics is acquired from the established vendors of the market. Our robust infrastructure unit is equipped with latest equipment and machines, that facilities faster production of quality-assured products. We also render customization service to our clients in order to meet their specific requirements. Unicottex Fabrics has 4 plants all located in Rakhial, producing different kind of fabric.
Business Type Year of Establishment Produciton/Annum Annual Turnover Total Number of Employees
Manufacturer Supplier 1988 Approx 3 Million Meters INR 150 Million Approx 100 Approx
SWOT ANALYSIS OF UNICOTTEX FABRICS (YEAR 2011)
ORGANISATION CHART
FACTORY LOCATION
The factory of Unicottex Fabrics is located in Rakhial which is considered to be the idle place for the weaving industry because of the proximity of the suppliers and customers. From many years many weaving units are installed in Rakhial and vicinity area. For Unicottex Fabrics the reasons for selecting Rakhial for installing a new unit are as follows: ? ? ? ? ? ? ? Proximity to suppliers of raw material Proximity to customers Proximity to the textile process plants Proximity to the textile spear parts dealers Less transportation cost Easy availability of workers Presence of the textile industry in Rakhial
Factory Address: Tejendra Industrial Estate, Opp. Reliance’s Petrol Pump, Rakhial, Ahmedabad-380023.
FACTORY BUILDING
Unicottex Fabrics has a single storey factory building. It is idle practice in weaving industry to have single storey factory building because the machineries are quite heavy in nature and it is somewhat difficult to move the materials also in multiple storey building. We have flourished a top-of-the-line infrastructure unit that is spread over a vast area. This unit is installed with advanced machines and sophisticated technology that facilitates and faster production of quality-assured products. We have segmented this unit into various departments such as manufacturing, and warehousing & packaging. This enables us to carry out all the production processes simultaneously in a hassle-free manner. Manned by highly trained professionals, this well organized unit assists us in meeting the bulk orders with in stipulated time.
Reasons for selecting Single Storey Building
? Better support for heavy machines. ? Better and faster movement of material and output. ? Faster evacuation in case of fire. ? From the view point of the safety of the workers it is always advisable. ? No need of vertical transportation of raw materials and product.
FACTORY LAYOUT
PURCHASE MANAGEMENT
Purchasing of raw materials and supplies is an important task for manufacturing firm. General Manager is responsible for the task of purchasing at Unicottex Fabrics. The main task for the General Manager in purchasing is the procurement of yarns as it is the main raw material. Purchasing of yarns is comprised of several steps which are as follows: 1. Once the order is received from customers the complete specification is given to the buyer about the product quality and yarns to be used (quality, count, and the mill of the yarn supplier). 2. Once it is approved by the buyer prices are obtained from different agents for the required yarn quality and quantity along with the date of delivery. 3. Quotations are received from different agents regarding the required yarn along with the terms and conditions related with the purchase. 4. Evaluation of the quotation is done by the General Manager. 5. The order for the yarn is placed with the agent whosoever offers the best price and flexible terms and conditions for the required yarn.
Note: The agent of the yarn is responsible if the yarn received is not as per the specifications given by Unicottex Fabrics. Unicottex Fabrics may not accept the goods in such case. For purchasing of yarns Unicottex Fabrics always rely on multiple sources as it provides following advantages to the firm: I. II. III. Obtaining the best possible prices. Bargaining power of the firm increases. It provides more flexible purchasing.
Factors considered by Unicottex Fabrics while selecting the source
I. II. III. IV. V. VI. VII. VIII. Reliability of the supplier and the agent. Ability to meet the order on time. After sale services given by the agent. Past Experience. Location of the supplier. Buying convenience. Financial position of the supplier. Discount offered.
INVENTORY MANAGEMENT
The term inventory includes raw material, work-in-process, finished goods and stores and spares. Inventory management involves administration, policies and procedures to reduce inventory cost.
The categorisation of inventory at Unicottex Fabrics is done in 3 parts:
PRODUCTION INVENTORY: It includes yarn, the most essential product to produce any fabric. MRO INVENTORIES: It includes oil, spare parts of the machine, etc. FINISHED GOODS INVENTORIES: Grey Fabric
Inventory Required for Production
Inventory Yarn MRO Inventory % of Total Inventory 90 10
RAW MATERIAL: YARN
Policy followed in management and control of yarn: Just in Time
Yarn is a basic raw material required to produce any fabric. Its requirement is actually dependent on the quality of fabric to be made. Unicottex Fabrics follows the policy of Just in Time (JIT) to maintain the inventory of yarn. Apart from that yarn prices are highly fluctuating in nature so it is actually advisable to acquire the yarn whenever required to gain maximum advantage of price fluctuations.
There are several advantages of following JIT policy for Unicottex Fabrics. They are as follows: Reduction in working capital investment: Yarn constitute about more than 90% of
inventory of any fabric producer. The yarn prices for the products of Unicottex Fabrics are quite high, so by following JIT technique the company can reduce its investment in yarn.
Reduction in storage costs: Yarn is the most essential and important raw material and it is
required to be stored carefully. Hence by following JIT technique the company is actually able to reduce its storage costs.
It leads to better quality control of the yarn. It also leads to reduction in wastages and better utilisation of yarns.
Note: Unicottex Fabrics is able to stand firm by following JIT technique in the recent price fluctuations of yarn, which are proven very adverse for the other companies.
MRO INVENTORIES
MRO inventory includes inventory of oil and spare parts of the machine. It is required to keep the machine up to date and for smooth and damage less production of the fabric.
Inventory of Oil
Unicottex Fabrics places blanket orders for purchasing oil. It is generally given for one financial year. The blanket order for the current financial year is placed with Ankur Oils. Unicottex Fabrics maintains only the required inventory of oil and rest is kept with the seller. Generally the similar policy is followed by other firms also in the industry since it holds very less part of total inventory.
Inventory of Spare Parts
It includes machine parts like shuttles, belts, frames, chains, etc. Unicottex Fabrics has given contract to J.R. Patel and Co. for supply of spare parts for the current financial year. In this case parts are supplied by J.R.Patel and Co. whenever it is needed by Unicottex Fabrics and the supplier is responsible for its complete replacement if the part is damaged. Very minimal inventory of spare parts is maintained on the factory, hence it reduces the storage cost and its maintenance cost.
FINISHED GOODS INVENTORY
The only finished goods inventory for Unicottex Fabrics is the Grey Farbic. Unicottex Fabrics follows the policy of supplying grey fabric once the output level for one order placed by the buyer reaches 5000 Meters. The arrangement of managing finished goods inventory is done such that the inventory of grey fabric doesn’t exceed 15,000 Meters at any point of time.
Note: However early/delayed deliveries can be done at prior request of the buyer.
Advantages of following above policy:
The prime advantage is the reduction in the storage cost of the grey fabric. Another advantage is the reduction in the transportation cost per meter of the grey fabric.
STORES MANAGEMENT
Meaning: Storage is the function of receiving, storing and issuing materials. Stores ensure
ready accessibility of major materials there-by efficient service to users. Minimisation of stores cost, and continuous supply is the prime function of the stores. At Unicottex Fabrics store is used to keep the inventory of yarns, grey fabrics, spare parts and oils. Unicottex Fabrics has allocated around 1500 square feet area for stores. It follows fixed location policy to store different materials for easy identification and speedy movement of the inventories.
STORES LAYOUT
Snapshot of Store Room
STOCK VERIFICATION
Store Keeper is responsible for the task of stock verification. FIFO method is used in determining the value of stock.
THE PRODUCTION PROCESS:WEAVING
The production process of grey fabric is not difficult as it includes only one raw material that is yarn. However it is somewhat complex because it requires calculations. Here I am not going to talk about those lengthy calculations, rather I will draw attention on how actually the fabric is made in some deep details about the raw materials used and the process to produce the grey fabric. The process of weaving can be determined as follows:
RAW MATERIAL: YARN
The basic and the most important raw material required for manufacturing grey fabric is yarn. Now let’s understand about the yarn and its different kinds in detail.
Description: Yarn is a long continuous length of interlocked fibres which is used in textile to
produce fabric. It is one kind of thread. It is one kind of filament, fibre or thread which is used to made cloth. The word originally referred only to woven fabrics but now includes knitted, bonded, felted, and tufted fabrics as well. Yarn is generally made from raw cotton. However now a days it is also made from nylon, polyester, viscose, wool, etc. It is generally denoted by count. Higher the count thinner is the thread and lower the count thicker is the thread.
Note: Cotton yarns are denoted by Ne, while Texturized yarns are denoted by Denier.
Type of Yarns
Single Yarn
Single, or one-ply, yarns are single strands composed of fibres held together by at least a small amount of twist; or of filaments grouped together either with or without twist; or of narrow strips of material; or of single man-made filaments extruded in sufficient thickness for use alone as yarn (monofilaments).
Twisted Yarn
Single yarns of the spun type, composed of many short fibres, require twist to hold them together and may be made with either S-twist or Z-twist. Single yarns are used to make the greatest variety of fabrics. This kind of yarn is generally used in premium shirting fabric. 2/60 count is the most common count in producing premium shirting.
Ply Yarn
Ply, plied, or folded, yarns are composed of two or more single yarns twisted together. Twoply yarn, for example, is composed of two single strands; three-ply yarn is composed of three single strands. In making ply yarns from spun strands, the individual strands are usually each twisted in one direction and are then combined and twisted in the opposite direction. When both the single strands and the final ply yarns are twisted in the same direction, the fibre is firmer, producing harder texture and reducing flexibility. Ply yarns provide strength for heavy industrial fabrics and are also used for delicate-looking sheer fabrics.
Novelty Yarns
Novelty yarns include a wide variety of yarns made with such special effects as slubs, produced by intentionally including small lumps in the yarn structure, and man-made yarns with varying thickness introduced during production. Natural fibres, including some linens, wools to be woven into tweed, and the uneven filaments of some types of silk cloth are allowed to retain their normal irregularities, producing the characteristic uneven surface of the finished fabric. Man-made fibres, which can be modified during production, are especially adaptable for special effects such as crimping and texturizing.
Filament Yarn
Filament yarn consists of filament fibres (very long continuous fibres) either twisted together or only grouped together. Thicker monofilaments are typically used for industrial purposes rather than fabric production or decoration. Silk is a natural filament, and synthetic filament yarns are used to produce silk-like effects.
Texturized Yarn
Texturized yarns are made by a process of air texturizing, which combines multiple filament yarns into a yarn with some of the characteristics of spun yarns.
WARP AND WEFT YARNS
In weaving, the warp, or lengthwise, yarns are subjected to greater stress and are usually stronger, smoother, and more even and have tighter twist than the weft, or crosswise, yarns. A sizing (stiffening) material such as starch may be applied to warp yarns, increasing their strength to withstand the stresses of fabric construction operations. Weft yarns, subjected to little stress during weaving, may be quite fragile.
YARNS USED BY UNICOTTEX FABRICS
COTTON YARN: Made from raw cotton. Unicottex Fabrics used carded and combed cotton
yarns which are bought from well known mills of India like Maharaja Pali Mills, DCM Mills, Nahar Spinning Mills, Vardhman, etc. through their appointed agents. 40 Ne, 50 Ne, 32 Ne, 30 Ne, 2/60 Ne are the regular used cotton yarns by the Unicottex Fabrics.
POLYESTER COTTON (PC) YARN: It is a blend of polyester and cotton.
Blends Available: 48:52 (48% Polyester and 52% Cotton)
65:35 (65% Polyester and 35% Cotton) 70:30 (70% Polyester and 30% Cotton) 85:15 (85% Polyester and 15% Cotton) 65:35 PC blend is regularly used by Unicottex Fabrics and it is bought from Asarva Mills (Ahmedabad) and Chorus Mills (Vankaner) through their appointed agents.
POLYESTER VISCOSE (PV) YARN: It is an organic yarn. It is a blend of polyester and
viscose.
Blends Available: 48:52 (48% Polyester and 52% Viscose)
65:35 (65% Polyester and 35% Viscose) 70:30 (70% Polyester and 30% Viscose) 80:20 (85% Polyester and 15% Viscose) 65:35 PV blend is regularly used blend by Unicottex Fabrics and it is bought from Sounderaja Mills, Rajasthan Textile Mills, Sangam Mills and Maharaja Pali Mills from their appointed agents.
Note: The approximate yarn usage of Unicottex Fabrics for 1 month is around 10 tons.
WARPING
Warping is the processing of creating the base yarn that runs top to bottom on woven cloth. Through warping the warping yarn is inserted into a warping beam which is finally attached at the back of the weaving loom. The primary objective of the warping process is to provide a continuous length of yarn from individual wound yarn packages, in sheet form to a beam for the succeeding process. When utilizing any technique in the warping process it is important to minimize end breaks, keep a constant and uniform tension on the yarns, keep a constant yarn speed, and insure quick response braking of the warper. These factors play a large role in the quality of the warp yarns, which in turn influences the runability of that warp yarn in the succeeding process.
SIZING
Sizing of the warp yarn is essential to reduce breakage of the yarn and thus production stops on the weaving machine. On the weaving machine, the warp yarns are subjected to several types of actions i.e. cyclic strain, flexing, abrasion at various loom parts and inter yarn friction. With sizing the strength - abrasion resistance - of the yarn will improve and the hairiness of yarn will decrease. The degree of improvement of strength depends on adhesion force between fiber and size, size penetration as well as encapsulation of yarn. Different types of water soluble polymers called textile sizing agents/chemicals suchasmodified starch, polyvinylalcohol (PVA), carboxymethyl cellulose (CMC), acrylates are used to protect the yarn. Also waxis added to reduce the abrasiveness of the warp yarns. The type of yarn material e.g. cotton, polyester, linen,... the thickness of the yarn, type of weaving machinery will determine the sizing recipe. The sizing liquor is applied on warp yarn with a warp sizing machine. After the weaving process the fabric is desized (washed).
WINDING
Yarn cannot be inserted directly through cones. Yarn is inserted into bobbins. This process is called winding. And these bobbins are inserted into shuttles for the purpose of weft insertion in the weaving process.
WEAVING PROCESS
Woven cloth is normally much longer in one direction than the other. The lengthwise threads are called the warp, and the other threads, which are combined with the warp and lie widthwise, are called the weft. An individual thread from the warp, of indefinite length, is called an end; each individual length of weft, extending from one edge of the cloth to the other, is called a pick, or shot. Consecutive picks are usually consecutive lengths of one piece of weft yarn that is repeatedly folded back on itself. In all methods of weaving cloth (except the rudimentary form of darning), before a length of weft is inserted in the warp, the warp is separated, over a short length extending from the cloth already formed, into two sheets. The process is called shedding and the space between the sheets the shed. A pick of weft is then laid between the two sheets of warp, in the operation known as picking. A new shed is then formed in accordance with the desired weave structure, with some or all of the ends in each sheet moving over to the position previously occupied by the other sheet. In this way the weft is clasped between two layers of warp. Since it is not possible to lay the weft close to the junction of the warp and the cloth already woven, a further operation called beating in, or beating up, is necessary to push the pick to the desired distance away from the last one inserted previously. Although beating in usually takes place while the shed is changing, it is normally completed before the new shed is fully formed.
The sequence of primary operations in one weaving cycle is thus shedding, picking, and beating in. At the end of the cycle the geometrical relation of the pick to the warp is the same as it would have been if the pick had been threaded through the spaces between alternate ends, first from one side of the cloth and then from the other, as in darning. This is the reason the weaving process is considered an interlacing method.
KIND OF WEAVES AT UNICOTTEX FABRICS
Plain Weave
1 Up 1 Down Plain Weave Plain weave is the simplest and most common of all weaves, requires only two harnessses and has two warp and weft yarns in each weave unit. To produce it, the warp yarns are held parallel under tension while a crosswise weft yarn is shot over and under alternate warps across the width of the web. The weave unit is completed at the end of the second row, when the weft has been inserted over and under the opposite set of warps, thus locking the previous weft in place. Fabric length is increased with the insertion of each succeeding weft yarn. When warp and weft yarns are approximately equal in size and quantity, the finished fabric is balanced and potentially stronger than cloth made of the same kind and number of warp and weft yarns in any other basic weave. At Unicottex Fabrics around 70-80% fabric is made using plain weave.
Note: In plain weave ends per inch is equal to the picks per inch. Around 80% of the total fabric in the world is made in plain weave.
Twill Weave
3/1 Twill (3 up, 1 down)
Left to Right Twill
Twill weave is distinguished by diagonal lines. The simplest twill is that created by the weft crossing over two warp yarns, then under one, the sequence being repeated in each succeeding shot (pick), but stepped over, one warp either to the left or right. Twills with more warps than wefts floating on the fabric’s face are called warp faced; those with wefts predominating, weft faced. The angle of the twill can also vary.
Commonly Used Twills in Weaving Twill
2:1 3:1 2:2 (Balanced) 3:3 (Balanced)
Interpretaion
2 up, 1 down 3 up, 1 down 2 up, 2 down 3 up, 3 down
Note: Twill weave is commonly used in producing denim fabric. At Unicottex Fabrics twill weave is used in manufacturing shirting fabric.
Satin Weave
Although satin-weave drafts superficially resemble those of twills, satin weave does not have the regular step in each successive weft that is characteristic of twills. Thus, there is no strong diagonal line, and the fabric is smooth faced, with an unbroken surface made up of long floating warp yarns. A true satin must have at least five warp and weft yarns in each complete weave repeat and thus requires at least five harnesses. Most satin fabrics are made of smooth, lightly twisted yarns that heighten the effect of light unbroken by visible crosswise bindings. The limited number of interlacings allows the weaver to use a proportionately large number of warp yarns and thus produce a heavy textured cloth that can be arranged in smooth, shadowed folds. Satins, having long floats, are susceptible to the wear caused by rubbing and snagging and are, therefore, generally regarded as luxury fabrics. Satin weaves are generally used in premium shirtings and high quality bed sheets. Unicottex Fabrics also uses satin weaves in its 47” cotton satin.
PRODUCTION TECHNOLOGY
Unicottex Fabrics is a manufacturer of premium grey and shirting fabrics. It manufactures all categories of grey fabrics be it Cotton, PC or PV. For the purpose of best weaving they have it is equipped with 24 high speed Ruti-B looms which are considered to be the best for premium weaving solutions. The looms have the capacity to produce 50000 Meters of grey fabrics every month. The technical specifications of the Ruti-B looms are as follows.
Ruti-B
Technical Specifications of Ruti-B Particulars
Manufacturer Speed Reed Width (in Inch) Weft Insertion Motor Weaving Solutions
Specifications
Sulzer (Switzerland) in association with Mafatlal Mills, Ahmedabad 220 RPM 48” Upto 200 picks/minute 1.5 HP Plain, Twill, Satin
Snapshots of Ruti-B
WARP BEAM
THE USE OF CAD @ UNICOTTEX FABRICS
The use of CAD in textile industry is increasing day by day. Unicottex fabrics realises its importance and uses CAD softwares like DB Weave and Weave Point to design its shirting fabrics. The use of CAD gives advantages in many ways like, it helps in better design of fabrics, improved production, less wastages and reduced manufacturing and design cost. Human errors in designing is also taken care of in CAD systems.
Screenshot of DB Weave
PEOPLE
People are the most valuable asset of any organisation, and at Unicottex Fabrics also we understand the value of the people that are connected with the company. Unicottex Fabrics has certain criteria for the recruitment of workers and it always believes in maintaining long term relationship with its workers. It also offers training programmes to its workers for increasing their effectiveness.
Employee Structure
Employee Strength Workers associated with the production Jobbers Production in Charge Helper Mending Folding 20 6 + 3 Relievers 2 1 4 1 1
Note: Labours associated with shedding of beams are not part of employee structure of Unicottex Fabrics.
Workers directly associated with production
Responisibilities
? To ensure continuous and damage less production. ? Communication and co operation with the jobber.
Criteria of Recruitment
? Experience of minimum 5 years in weaving department. ? Ability to solve minor technical problems. ? Flexibility (can be asked to work in any shift)
Jobber
Responisibilities:
? Maintenance of machinery. ? Co-operate with workers. ? To ensure damage less and continuous production.
Criteria of Recruitment:
? Minimum 10 years of experience as jobber in weaving department of Ruti B machines. ? Flexibility. ? Communication skills (Hindi, Tamil, Gujarati) ? Must have up to date technical knowledge of Ruti B machines.
Production in Charge
Responsibilities
? Responsible to meet the production as per the standard. ? Responsible for recruitment of the workers for production and of jobbers. ? Responsible to ensure that all the shifts of production are working as per the schedule. ? Responsible to design reward policies for the workers directly associated with production. ? Communication and co-operation with the jobbers, workers and the management.
Criteria of Recruitment
? Minimum 10 years of experience as production in charge in weaving department. ? Communication skills (Hindi, English, Gujarati, Tamil) ? Must have technical knowledge of all aspects of weaving machineries.
WAGES AND SALARIES
Workers directly associated with production
Wage Pay Policy Wage for 1 worker/Shift (12 Hours) (Working of 26 days) Bonus Reward Policy Fix Pay System + Reward Rs. 250 8.33% of total annual wages Rs. 20/Day additional if a worker is present on all working days. Workers Insurance Scheme by ATIRA Workmen Compensation Insurance by United India Insurance Company Training programmes offered by ATIRA
Benefits
Training
Note: Relievers are also paid same amount, however they are not entitled for any rewards.
Wages of Helper, Mender and Folder
Helper Mender Folder Wages Bonus Rs. 100/ Day Rs. 0.12/Meter Rs. 75/ Loom/Month 8.33% of total annual wages
Jobbers
Wage Pay Policy Wages paid to jobber/day Bonus Benefits Workmen Compensation Insurance by United India Insurance Company Fix Pay System Rs. 475 for 12 hour shift 8.33% of total annual wages Workers Insurance Scheme by ATIRA
Production in Charge
Salary Policy Salary/Month Bonus Benefits Workmen Compensation Insurance by United India Insurance Company Is entitled for training and development programme offered by ATIRA Fix Pay System Rs. 18000 10% of total annual salary Workers Insurance Scheme by ATIRA
Training
QUALITY MANAGEMENT @ UNICOTTEX FABRICS
Quality: Quality may be defined as the sum total of features of a product which influence its
ability to satisfy a given demand.
Dimensions of the product quality
? ? ? ? ? ? ? Performance of the product Features of the product Reliability of the product Serviceability of the product Appearance of the product Customer Service/After sales support Safety
Quality Control: Quality control is an effective system for integrating the quality
development, quality maintenance and quality improvement efforts of the various groups in an organisation so as to enable production and service at the most economical levels which allow for full customer satisfaction. Quality control helps to minimise the costs of inspection and rejection. At Unicottex Fabrics Quality Control is given foremost priority and the task is performed by everyone in the organisation be it top management, middle management or bottom level management. Everyone is involved in controlling the quality of the product. At Unicottex Fabrics Quality Control is done in different stages and by different departments. Quality Control in designing of the product and purchasing of the raw material is done by the top management, while care of quality while manufacturing is taken by the production in charge and the jobbers. After sales support and communication with buyers is done by the appointed agents. Now let’s understand how the quality control work is done by different departments:
QUALITY CONTROL IN DESIGNING OF THE GREY FABRIC & PURCHASE OF YARNS
This task is performed by the General Manager. There are several steps involved in this task which are as follows: I. First when the order is received from the buyer, clear communication is done with him regarding the specifications of the product, yarns to be used, density of the yarns, the use of the grey fabric etc. Once the product specifications are received grey fabric is designed on computer. Fabric designing requires lengthy calculations like calculations of set length, fabric width, weight of the fabric, etc. For this purpose softwares are used to arrive at accurate designing of the product. Once the fabric is designed and yarn requirement is calculated, yarn is ordered through our appointed agents. It is generally bought from finest mills of India. The final fabric quality is ultimately depended on the yarns used. For quality assurance to customer Unicottex Fabrics only uses yarns of mills and does not purchase yarns from local suppliers. Further when the yarn is received from the supplier it is checked by the production in charge and the general manager to ensure that it is as per the specifications. Once the complete designing is done a printed sheet regarding all details of the product to be manufactured is handed over to the production department.
II.
III.
IV. V.
QUALITY CONTROL IN MANUFACTURING OF THE GREY FABRIC
This task is performed by the production in charge along with the jobbers and the workers. It includes following tasks: I. II. III. Before installing a new cloth beam on the machine, machine is properly inspected, cleaned and lubricated so that the new cloth beam runs smoothly. Parts of the machine like shuttles, reed frames, and chains are up to date and are not defective. For smoother production of the grey fabrics air coolers are installed in the plant which maintains required humidity in the plant. Without required humidity the fabric looks dull and rough. Once the production is started, daily samples of the fabric are taken to check the width of the fabric is as per the specifications. It is one of the important tasks because width of the fabric changes in different processes. Note: If the fabric width is not as per the specifications or there are any damages in warp then reshedding process is done. Once the grey fabric is produced it goes to mending department where all the excess threads of the fabric are removed and then it goes to folding department for folding. For accurate calculation of the fabric folded electronic devices are attached with the folding machine. Once the fabric is folded it is stored in storage department. For the quality assurance of the final grey fabric storage department is kept clean and neat so as to avoid any damage to the fabric.
IV.
V.
VI.
QUALITY CONTROL AFTER DELIVERY OF THE GREY FABRIC
Once the grey fabric is delivered to the buyer our appointed agents comes in contact with the buyers to ensure that product delivered is as per the buyer’s specifications. Further if the buyer wants any changes in future deliveries of the product it can also be done through communication with our agents. Unicottex Fabrics believes in customer first policy. It encourages complaints of buyer so as to avoid the same mistake in future. Customer complaints regarding any feature of the product always encourage us to concentrate more on quality.
BENEFITS OF QUALITY CONTROL
I. II. III. IV. V. VI. VII. VIII. Reduced wastage of yarn. Reduced cost of labour per meter of fabric. Improved fabric quality. Reduction in inspection costs. Increased production. Higher operating efficiency due to reduced wastages and damages. Better utilisation of resources. Better customer satisfaction.
MAINTENANCE MANAGEMENT
Maintenance is the function of the production department and it is headed by the production in charge in Unicottex Fabrics. The prime task of the maintenance team is to keep the plant and the machineries in sound condition. The following tasks are performed by the maintenance team at Unicottex Fabrics: I. II. III. IV. V. Maintenance of the plant and the machineries. Inspection of the machines and lubrication. Waste disposal. Humidity and temperature control in the plant. Plant protection.
Maintenance Policy Planned Maintenance
Unicottex Fabrics follows policy of planned maintenance. Maintenance of plant and machinery is scheduled on every 15th day during staggering. The entire plant is shut down on that day because of staggering and the maintenance team does the work on that day.
Routine Maintenance
Apart from planned maintenance routine maintenance is also done during the work. It includes oiling and lubrication of the machine, cleaning, etc.
PRODUCT & PRICE
PRODUCT PORTFOLIO
We are a reliable manufacturer and supplier of an enticing collection of Cotton, PV & Other Fabric. Our fabrics find extensive application in various sectors of the textile industry. These fabrics are well-known in the market for their unique designs, exotic colors, colorfastness, skin-friendliness and shrink-resistance. Considering the diverse demands of the clients, these fabrics are made available in varied sizes, colors, designs and patterns. Our range includes following products:
? ? ? ? ?
Cotton Fabric PV Fabrics PC Fabrics Shirting Fabrics Handkerchief Fabrics
PRICING
Unicottex Fabrics follows mark up pricing policy. In which a certain percentage of markup is added to the total cost of the fabric. In all the products manufactured, Unicottex Fabrics follows the same policy of pricing. Different factors like competition, demand of the product, quality of the product are considered while pricing the product. The percentage of mark up varies as per the different situations, but the pricing policy remains the same.
COTTON
We are instrumental in offering a qualitative range of cotton fabrics to our esteemed clients. These fabrics are widely used for designing various garments and dresses. Our fabrics are offered in a wide variety of density, width and weaving style to meet the diverse demands of the clients.
Density Yarn Count Width Techniques Style Use Price/Meter
120*72 40*40 (Cotton) 47” Woven Satin Garment, Home Textile Rs. 35 (Subject to change)
Density Yarn Count Width Techniques Style Use Price/Meter
128*72 2/60*2/60 (Cotton) 47” Woven Plain Shirting Rs. 60 (Subject to change)
POLYESTER COTTON FABRIC
We are engaged in offering a sophisticated range of PC fabrics to our prestigious clients. Our range caters to the requirements of various industries. PC fabrics offered by us are manufactured employing high quality raw materials and advanced production techniques. It is used for multi purposes like printed fabrics, ladies wear, men’s apparel, etc.
Density Yarn Count Blend Width Techniques Style Use Price/Meter
96*72 45*45 PC 65:35 47” Woven Plain Shirting, Home Textiles Rs. 32 (Subject to change)
Density Yarn Count Blend Width Techniques Style Use Price/Meter
110*76 45*45 PC 65:35 47” Woven Plain Shirting, Home Textiles Rs. 34 (Subject to change)
Density Yarn Count Blend Width Techniques Style Use Price/Meter
88*64 45*45 PC 65:35 47” Woven Plain Shirting, Home Textiles Rs. 29 (Subject to change)
POLYESTER VISCOSE FABRIC
Our polyester viscose fabric is manufactured by using high quality of PV yarn acquired from popular mills of India. These fabrics are well-known for their attributes such as shrink-resistance, durability, colour fastness. These fabrics are fully customised as per customer’s specification in terms of density, width of the fabric and weaving pattern. These fabrics are highly demanded for its softness. It is generally used in ladies dress materials, shirting and fashionable scarves.
Density Yarn Count Blend Width Techniques Style Use Price/Meter
96*92 (Slub) 40*40 PV 48:52 38” Woven Plain Shirting Rs. 33 (Subject to change)
Density Yarn Count Blend Width Techniques Style Use Price/Meter
84*80 40*40 PV 65:35 38”/60” Woven Plain Shirting, Dress Materials Rs. 28 (Subject to change)
SHIRTING FABRIC
We present forward to our esteemed clients a steadfast range of shirting fabrics at market leading prices. These fabrics are made accessible in yarn dyed and printed type. We have tie up with best manufacturers of the shirting grey fabric to provide unmatched quality of shirting fabric. We are able to supply different varieties of shirting fabrics like plain, check, cotluk check, filafil, etc. This fabric is available in the width of 58”.
CHECK SHIRTING FABRIC
Density Yarn Count Width Techniques Style Use Price/Meter
76*72 2/60*2/60 100% Combed Cotton 57-58” Woven Plain Men’s Shirting Rs.90/ Meter
SLUB CHECK FABRIC
Density Yarn Count Width Techniques Style Use Price/Meter
80*72 40*40 Combed Cotton 57-58” Woven Plain Men’s Shirting Rs.95/ Meter
COTLUK FILAFIL CHECK FABRIC
Density Yarn Count Width Techniques Style Use Price/Meter
80*72 180*180 Denier 57-58” Woven Plain Men’s Shirting Rs.95/ Meter
HANDKERCHIEF FABRIC
We have for our prestigious clients a comprehensive gamut of handkerchief Fabrics. These fabrics are manufactured using 100% cotton, which is acquired from the trusted vendors of the market. In order to cater to the specific requirements of our clients, we customize these products on following parameters: ? ? ? Designs Colours Patterns
The price of the handkerchiefs is completely dependent on its pattern and quality so it is not disclosed here. However the same pricing policy i.e. Markup pricing policy is also followed here.
PLACE
DISTRIBUTION CHANNEL
A distribution channel performs the work of mooving the goods from producers to consumers. Unicottex Fabrics follows the policy of Selective Distribution. Unicottex Fabrics does not have any shop or outlet to distribute its products. Products are generally sold and distributed either directly or through appointed agents. Thus it operates through both direct and indirect chains of distribution.
DIRECT MARKETING CHANNEL
ONE LEVEL CHANNEL
Total Agents: 4 Commission Paid: 0.5% of the sales value
ROLES AND RESPONSIBILITIES OF APPOINTED AGENTS
? ? ? ? To carry out timely delivery. To execute trade promotion tools. To communicate terms and conditions related with the goods to the buyer. To maintain relationship with company and the buyers.
MARKETING FLOWS IN DISTRIBUTION CHANNEL
PHYSICAL FLOW (FORWARD FLOW)
TITLE FLOW (FORWARD FLOW)
Agents (Does not take title of the goods)
Unicottex Fabrics (Manufacturer)
Buyer/Customer
PAYMENT FLOW (BACKWARD)
INFORMATION FLOW (BOTH SIDED)
RISK FLOW
PROMOTION
Promotion is an integral part of any business. For an industry like textile promotion is certainly limited to trade discount and cash discount. Cash discount has become essential for the textile industry to generate speedy payments because credit period is quite long in this industry. However for weaving industry credit period on an average is of about 30 days.
Promotion Policy at Unicottex Fabrics
Credit Period Offered: 15-30 Days after the delivery of the goods.
Trade Discount: No trade discount is given by the firm except the order is above 15000
Meters. If the order is above 15000 meters 1% trade discount is given to the buyer.
Cash Discount: Unicottex Fabrics follows cash discount policy of 2/10 net 30 terms.
Note: Special offers and discounted price is offered to buyers in case of surplus stock.
ONLINE MARKETING
In this era of internet and technology online marketing has made its distinct place now. Earlier online marketing was generally done for consumer goods, travel and tourism products, etc. But now a day’s industrial products are also marketed through B2B marketplace. Unicottex Fabrics has also understood the importance of online marketing and advertising and has collaborated with Indiamart Intermesh Ltd to market its products. Unicottex Fabrics has designed its online catalogue with www.indiamart.com and buyers from 196 countries can inquire about the products of Unicottex Fabrics.
Snapshot of webpage of Unicottex Fabrics
Product Showcase The online catalogue of Unicottex Fabrics is designed keeping in mind that potential buyers can easily navigate through the webpage and can inquire about the products of the company easily by making a free call, sending free sms or by sending an email. The products showcase facility is also available on the webpage of Unicottex Fabrics so that buyers can easily navigate through different products of the company and can have a closer look at it. Apart from it Unicottex Fabrics also gives banner ads in the category of Fabric and Textiles on www.indiamart.com so that any potential buyer can easily come on the webpage of Unicottex Fabrics.
Advantages of Online Marketing to Unicottex Fabrics
I. II. III. IV. V. Internet marketing is inexpensive compared to the other Medias of advertising. The cost of reaching the target audience is low. More widely reach of target audience. Multimedia effects like videos, images, banners can be used. Customers can inquire easily without incurring any cost. Export order queries from more than 196 countries.
LEARNINGS @ UNICOTTEX FABRICS
Before taking the decision of doing MBA I was pretty sure that I will start my own venture and do something related to our family business. Since the completion of my graduation I’ve been going to Unicottex Fabrics and learning new thing and dimensions of textile industry. During this so called Summer Internship training I enhanced my learning in the textile industry. I learned new insights in production and marketing. Production being the toughest for any manufacturing industry an entrepreneur starting a venture in production must know technical aspects. In Unicottex Fabrics I’ve learned many things in past 2 years and would learn new things before I start my new venture soon. I am very thankful to the Team Unicottex Fabrics for providing me such an important platform of learning entrepreneurship.
BIBLIOGRAPHY
Productions and Operations Management by K.Aswathappa and K. Shridhara Bhat Marketing Management by Philip Kotler
WEBOGRAPHY
www.google.com www.wikipedia.org www.britannica.com
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