BBA-IV

SAFIA ATTA(17-71), MUBRIKA AHMED(Evening 17-19)

Assignment 1
Production and Operation Management
 GUL AHMED
Gul Ahmed Textile Mills is pioneering the endless modification in textile industry of Pakistan
since 1953. It is a vertically integrated textile manufacturing organization involved in spinning,
weaving, yarn dyeing processing, designing, stitching and retail. The products include apparels
home textile, shoes, bags and much more. The story of textiles in the subcontinent is the story of
Gul Ahmed. The group began trading in textiles in the early 1900s. The group entered in the
field of manufacturing with the establishment of today’s iconic name of Gul Ahmed Textile
Mills Ltd in the year 1953.
Since its listing on the Karachi Stock Exchange in 1970, the company has been making rapid
progress and enjoying a leading position in the world of textiles. With an installed capacity of
more than 51,840 spindles, 300 state-of-the-art weaving machines and most modern yarn dyeing,
processing & stitching units, Gul Ahmed is a composite unit – making everything from cotton
yarn to finished products. Gul Ahmed has its own captive power plant comprising of gas
engines, gas & steam turbines, and backup diesel engines. Believing in playing its role in
protecting the environment, Gul Ahmed has also set up a waste water treatment plant to treat
100% of its effluent, bringing it to NEQS levels.
Gul Ahmed is playing a vital role not only as a textile giant, but has its strong presence in the
retail business as well. The opening of its flagship store – Ideas by Gul Ahmed– marked the
group’s entry into the retail business. Starting from Karachi, Gul Ahmed now has an extensive
chain of more than 40 retail stores across the country, offering a diverse range of products from
home accessories to fashion clothing. More than 50 years since its inception, the name Gul
Ahmed is still globally synonymous ith quality, innovation & reliability.

Subsidiary Companies

 Gul Ahmed International Limited. (FZC)-UAE – (Wholly owned subsidiary of Gul

Ahmed Textile Mills Limited)
 GTM Europe Limited – UK– (Wholly owned subsidiary of Gul Ahmed International
Limited. (FZC)-UAE)
 GTM USA Corp. -USA – (Wholly owned subsidiary of GTM Europe Limited – UK)
 Sky Home Corp.- USA – (Wholly owned subsidiary of GTM Europe Limited – UK)
Vision, Mission & Values

Vision
Enriching Lives by Inspiring Change.

Mission
To deliver value to our stakeholders through innovative technology, teamwork and by fulfilling our social
and environmental responsibilities.

Values
In achieving its vision and fulfilling its mission, the Company shall operate on the following core
values:
 Integrity
 Respect
 Passion
 Quality
 Teamwork

Business Activities
Excellence in quality and service is the hallmark of all operations performed at Gul Ahmed.
Firmly standing by its business values, Gul Ahmed is active in manufacture and sale of textile
products.
The manufacturing wing is an essential component in Gul Ahmed’s operations. The
manufacturing cycle, which includes spinning, weaving, processing, designing and stitching,
results in an end product that is tailored to the most stringent customer requirements.
On the retail front, Ideas by Gul Ahmed offers fabrics and made-ups, ranging from home
accessories to clothing. It not only provides fashion at great value, but also caters to various
customer needs by offering a diverse product mix. This leads to a complete and enjoyable retail
experience. As a result of this, the chain has expanded to 40 stores across Pakistan since its
inception in 2003.
 Products

Yarns
Gul Ahmed has been able to craft its place as a leading producer of value added fabrics from
Pakistan with a special emphasis on blended and yarn dyed fabrics. At Gul Ahmed, efforts are
made to strive and grow through learning, continuous improvement, and innovation.

The yarn produced by Gul Ahmed is exported to a host of countries around the globe who are
appreciative of the quality and pricing offered. The different regions that Gul Ahmed exports its
yarn to include:

 North/South America (USA, Brazil)

 Europe (Italy, Germany, Portugal, Poland, Ukraine, Russia, Turkey)
 Africa (Egypt)
 Middle East (Syria, UAE, Saudi Arabia)
 South-East Asia (Bangladesh, Sri Lanka, South Korea, Indonesia)
 Products

1. Carded Yarns
2. Combed Yarns
3. Compact Siro Yarns
4. Fancy Yarns
5. Piled Yarns
6. Core Spurn Yarns
7. Slub Yarns
8. Package Dyed/Cone Dyed
9. Gassed Mercerized/Dyed Yarn

Fabrics
Gul Ahmed is capable to dye and print the whole range of home textile and apparel fabrics. In addition
we also have setup for back coating and flock printing that gives us an added opportunity to serve the
needs of our customers.
Gul Ahmed is equipped with the most advanced technology that enables it to cater to a vast spectrum of
product varieties that include:

Products
1. Plain Fabrics
2. Sheeting Fabrics
3. Poplin Fabrics
4. Canvas
5. Oxford
6. Duck
7. Bedford Cord
8. Herringbone
9. Ottoman
10. Twill
11. Sateen
12. Rib Stops
13. Slub Fabrics
14. Stretch Fabrics
15. Mélange Fabrics

Made-ups
Gul Ahmed’s fine textile products represent a unique fusion of the centuries-old traditions of the
east and the latest textile technology of the west. The purest of cotton fibers, produced from the
fertile lands of the Indus Valley, are spun, woven and processed into the finest quality cotton and
blended products through a combination of latest technology, skills and craftsmanship of this
 traditional industry. The made-ups can be in white, dyed, printed or yarn-dyed form, and in
different styles of confectioning.
Products
Home Textiles

 Sheets and Pillowcases

 Comforters
 Quilt/Duvet covers
 Bed-in-a-Bag
 Decorative pillows
 Curtains
 Upholstery fabrics

Institutional Textiles

 Patient Gowns
 Scrub Suits
 Lab Coats
 Chef Coats
 Hospital Sheets
 Work Wear
 Doctors and Nurses Uniforms
 High Visibility Uniforms

Apparel

 Pyjama Suits
 Boxer Shorts
 Bermuda Shorts
 Casual Shirts
 Children’s Pyjama Suits
 Children’s Sleeping Bags

Top competitors and Alternatives

1. Khaadi
2. Sana Safinaz
3. Motifz
4. J.(Junaid Jamshaid)
5. Alkaram studio
6. Warda
7. Chinyere
Conversion Process

Spinning

Manufacturing starts from the core activity of textiles which is spinning. This is the twisting
together of drawn out strands of fibres to form yarn.
Since Gul Ahmed’s inception, spinning has been a basic and integral component. Gul Ahmed has
three spinning units having more than 51,840 spindles and 22,080 rotors equipped with machines
imported from UK, USA, Germany, Japan and China. These units are capable of producing a
wide range of yarn from 100% cotton to poly cotton, poly viscose, slub yarn, siro yarn and core
yarn. They have the capacity to produce 120 tons per day of average yarn count in 100% cotton.
The latest machinery is used in blow room lines and auto cone machines to eliminate any
possibility of contamination. Spinning capacity has recently been upgraded with the addition of
TRUCZSCHLER TC 11 carding machine, Rieter RSBD-22 drawing frame, and Murata 21C Q-
PRO auto coners.

Weaving
Weaving is a method of fabric production in which two distinct sets of yarns or threads are
interlaced at right angles to form a fabric.
Gul Ahmed has the most advanced Air Jet weaving production facilities, having a production
capacity of approximately 100,000 meters per day. The facility is operated by skilled workers
under the supervision of highly qualified professionals. The setup has 300 modern weaving
machines supported by cutting-edge back process machines. Through continuous improvement,
learning and innovation, Gul Ahmed is diversifying from basic grey fabric to value added fabric
including all kinds of dyed yarn fabric.

Yarn Dyeing
Adding color to textile products such as yarns, fibers, and fabrics is known as dyeing. It is done
through the use of special solutions and various chemical materials.
In 2007, a new project of yarn dyeing and mercerizing started at Gul Ahmed. As with all other
functions, highly qualified professionals manage the operations, leveraging their vast experience
and understanding of the quality requirements of diverse market segments. Gul Ahmed’s yarn
dyed fabric capacity based on 48 Air jet looms is about 350,000 meters per month.
Machinery and instruments are imported from Italy and USA.

Processing

A top quality product requires all the different processes to synergies in a perfect manner,
creating something unique as a result. This philosophy is truly reflected in the processing stage at
Gul Ahmed, one of the pioneers in fabric printing and dyeing. With the latest, cutting-edge
machines and equipment in use, the skilled professionals strive forward on their journey to be the
best.
Gul Ahmed considers quality as its key differentiator and there is a comprehensive and effective
quality control & assurance system to ensure process optimization in order to obtain output
efficiently and effectively. From pre-treatment to finishing, the entire process is aimed at adding
value and creating a product that is tailored to meet customer needs.

Design

Capturing the imagination of the audience requires having a creative approach coupled with a
thoughtful insight. Having an eye for detail and paying attention to the varied tastes are absolute
essentials towards creating appealing designs.
With this in mind, Gul Ahmed’s design studios are staffed with experienced artists who have the
capability to conceive the most creative concepts in design. Artists adapt different colorways to
meet the specifications of each individual country. European and US designers working for the
company continuously develop new designs for specific geographical areas. The designing team
visits major international exhibitions throughout the year to stay up-to-date with the current
market trends. The use of the latest CAD/CAM systems and the most sophisticated laser and wax
jet engraving technologies are examples of the company’s dedication to computerization in all
aspects of design detail and reproduction.

Stitching

Stitching is the process whereby fabric is fashioned into a finished product by means of different
sewing techniques. The stitching stage holds extreme significance to ensure that the product
takes its shape according to requirements. In itself a highly specialized field, stitching requires
care and precision.
Gul Ahmed’s stitching units see cloth automatically spread out and cut through sophisticated
machinery. Equipped with the necessary high-speed precision stitching machines, the trained
workforce moulds the fabrics into different sizes and shapes for varying requirements across
diverse markets.

Quality Control

Quality control is the process in which all factors involved in manufacture are checked for
meeting quality level requirements. In the field of textiles, the processing laboratory plays a key
role. It serves as the foundation for producing a quality product.
Gul Ahmed has one of the best textile laboratories equipped with state-of-the-art technology and
staffed with highly qualified personnel. It has the capability to cover a wide range of operations
from the testing of raw materials to the evaluation of finished products, according to customer
specifications. As a part of quality control for online checking, the processing laboratory is well
prepared to control and support the processing unit at every stage of production. For continuous
improvement in the quality of the end product, research and development is also carried out in
the laboratory.

Quality Policy

Gul Ahmed wants to maintain its position as one of the finest quality-managed companies
capable of meeting the requirements of its external & internal customers. Gul Ahmed’s culture
stresses employee participation & innovative technology application to achieve continuous
improvement. The efforts towards improvement of the quality system, based on the guidelines of
ISO 9000 series of standards, are a journey towards excellence.
Technology:

Spinning Machinery Overview:

Ring Open End Drawing

 Zinser C 351  Autocoro-8 &  Rieter RSB D-22, D-24
(Germany) Autocoro-9 with & D-26 (Switzerland)
35,040 Spindles Monitoring corolab +  Toyota DX8 (Japan)
 Lakhsmi LR9 (Indian) FF (Germany)
16,800 Spindles 22,080 Rotors

Autocone Carding Simplex

 Murata Q-PRO Plus  Rieter C-70  Simplex FL-16 (Japan)
with Uster Quantum- (Switzerland)
3 (Japan)  Trutzschler TC 11
 Savio Polar with Zenit (Germany)
Plus (Italy)  Trutzschler TC 15 IDF-
2 (Germany)

Comber Yarn Conditioning Machine Blow Room

 Rieter E 62  Xorella (Switzerland)
(Switzerland)  Welker (Germany)
 Pozzi (Italy)
 Rieter with Uster Jossi
Vision Shield-2 &
Magic Eye
(Switzerland)
 Truetzschler
contamination sorter
Securoprop SP – FPU
(Germany)
 Weaving Machinery Overview:

Warping Machine Sizing Machine Sampling Machines

 Benninger Sectional  Zel-Benninger  CCI SW 550 Winding
Warping (Switzerland) Computerized Ben Size Machine (China)
 Benninger Ben-Direct Tech (Switzerland)  CCI Single end sizing
Warping Computerized  Tsudakoma TTS20S (China)
(Switzerland) Sizing (Japan)  CCI Sample Weaving
 Tsudakoma Warping Machine Dobby (China)
TW10S (Japan)

Warp Tying Machine Preparatory Machinery Reed Cleaning Machine

 Warp Tying Staubli
 Fischer Warp Tying
 Exacta
 Fischer
 Staubli Delta-110
Drawing Machine
 Staubli Leasing Machine
 Spalleck Reed Cleaning
Machine
 SKR Ultrasonic Reed
Cleaning Machine

Oil Cleaning Machine Yarn Conditioning Rewinding

 Thermostat Yarn  Xorella Kleen oil micro  Murataa
Conditioning filtration machine  Mach coner
 Truetzschler
contamination sorter
Securoprop SP – FPU

Looms

 Ruti Looms – 150 CM

 Picanol Omni 800 Air Jet Looms – 190 CM
 Tsudakoma Zax Air Jet Looms – 280 CM
 Tsudakoma 9100 Dobby Air Jet Looms – 280 CM
 Tsudakoma 9100 Dobby Air Jet Looms – 340 CM
 Tsudakoma 9100 Tappet Air Jet Looms – 340 CM
 Tsudakoma 9100 Dobby Air Jet Looms – 210 CM
 Tsudakoma 9100 Tappet Air Jet Looms – 210 CM
 Tsudakoma 9100 Tappet Air Jet Looms – 210 CM
 Tsudakoma 9100 Air Jet Looms – 280 CM
 Picanol Rapier Looms – 300 CM
 Tsudakoma Zax Dobby Air Jet Looms – 340 CM
 Tsudakoma Zax Tappet Air Jet Looms – 340 CM
 Tsudakoma 9100 Air Jet Looms – 340 CM
 Yarn Dyeing Machinery Overview:
Production

 Singing & Reeling & Hank to Cone, Rite S.P.A (Italy)

 Soft winding & Rewinding, Rite S.P.A (Italy)
 Soft winding, Corghi (Italy)
 Soft winding, Fadis S.P.A(Italy)
 Rewinding, Suzhou Xinsanfang (China)
 Mercerizing, Jaeggli Meccanotessile (Italy)
 Mercerizing, Rite S.p.A (Italy)
 Hank Dyeing, Loris Bellini (Italy)
 Package Dyeing ( Cone Dyeing), Loris Bellini (Italy)
 Rapid Dryer, Loris Bellini (Italy)
 Radio Frequency Dryer, Stalam (Italy)
 Sampling Machine, Ugollini (Italy)
 Color Matching System, Data Color (USA)
 Auto Dosing System (Chemical / Dyes), Sate (Italy)

Laboratory/ Quality Control:

 Yarn Friction Tester, Mesdan (Italy)

 Yarn Twist Tester Machine, Mesdan (Italy)
 Crocking Machine, Mesdan (Italy)
 Lab Dips Dryer, Mesdan (Italy)
 Panel Machine/ Socks Machine, Mesdan (Italy)
 Hank Machine, Mesdan (Italy)
 Lab Dips Machine, Data Color (USA)
 Lab Dips Conditioner Machine, Data Color (USA)
 Spectro photometer, Data Color (USA)
 Auto Lab Dispensing / Solution Maker Machine, Data Color (USA)
 Multi precise Sample cone Dyeing Machine, Data Color (USA)
 Light Box, Data Color (USA)
 Processing Machinery Overiew:

Pre Treatment Dyeing

 Osthof (Germany)  Monforts (Germany))
 Menzil (Germany)  Goller (Germany)
 Goller (Germany)  Benninger (Switzerland)
 Kuster (Germany)  Kuster (Germany)

Printing Finishing
 Stork (Holland)  Monforts (Germany)
 Reggiani (Italy)  Arioli Tung Yung (Italy)
 Ichinose (Japan)  Krantz (Taiwan)
 Ramesh (Germany)

Stitching Machinery Overview:

Cutting Machines

 Diamond Machine (Nagle Harmin)

 Cutting Machines (Hauser / Gerber / KM / Mini Roller / Philips Sprider / Qili / Eastman)
 Tape Cutter (Local)
 Slicer (Myteck)
 Cropping Machine (Bella)

Buttons Machines

 Kaj Machines (Juki / Golden Wheel / Chinki)

 Button Machine (Juki / Golden Wheel / Chinki)
 Stud Button Machine (Automatic Giuzhou (China) / Manual (Local))

Lock Stitching Machines

 Single Needles Manual (Juki / Golden Wheel / Shingong / Singer / Brother)

 Single Needles Auto (Juki / Golden Wheel)
 Two Needle Machines (Juki / Golden Wheel / Brother / Gepsew)
 Bartack Machine (Juki / Chinki))
 Chain Stitching Machines

 Safety Machines (Juki / Golden Wheel / Pegasus / Brother)

 Blind Stitch Machines (Juki / Treasure / Precious / Tony)
 Chainstitch 12 needle (Kansai / Golden Wheel / Vario-Matic / Siruba)
 Chainstitch 25 needle (Vario-Matic)
 Chainstitch 33 needle (Gepsew)

Embroidery Machines

 Embroidery Machines (Tajima / Bordan)

 Zig Zag Machines (Juki / Brother)
 Saddle Stitching Machine (Juki)
 Picoting Machine (Barrato)

Quilting Machines

 Quilting Single Head (Delta / Kaybematic)

 Quilting Multineedle ( Mecca / Grabitz / Donyoung

Metal Detector Machines

 Metal Detector (Aolite / Hashima)

Shrink Wrap Machines

 Shrink Wrap Machine (3M Matic SMI Pack / Tayi Yeh)

Compress Machines

 Compress Machine (Sala)

Packing Machines Comforters

 Comforter Packing Machine (Kaybematic)

Embossing Machine

 Embossing Machine (Lazzer)