CONTENTS

CHAPTER NO CONTENTS PAGE

NUMBER
I Introduction to spinning
industry

II Organization Profile

III Spinning Process

IV Procedure and Methods of

Spinning

V Department And its Functions

VI Conclusion
 CHAPTER – I

INTRODUCTION TO SPINNING INDUSTRY

The textile industry has significantly benefited from technological advancement in the
last few decades. Advanced machines take care of each step of the textile spinning
process. In India it stands at a unique place and has maintained a sustainable
growth over the years. It has a significant role in India as it fulfills the essential and
basic needs of people. Currently India has the second highest spindle among the
world after China. The spinning sector is the second largest provider of employment
after agriculture. The spinning industry can be broadly classified into two categories,
the organized sector and the unorganized or decentralized sector. The organized
sector of the spinning industry represents the mills. It could be a spinning mill or a
composite mill. Composite mills are the one where the spinning, weaving and
processing facilities are carried out in one roof. The decentralized sector comprises
three segments. They are power loom, handloom and hosiery. In addition to the
above there are readymade garments, khaki manufacturing units in the decentralized
sector. Our country’s population was about 40 crores at the beginning of the 20th
century, the requirements of spinning materials were met by domestic production
and imports.

The spinning process involves multiple steps, from removing impurities to the final
step of the appropriately packaging fabric. The yarn spinning process, which was
primarily manual, is now completely automated. To ensure that the yarn can be
enhanced and used for textile manufacturing, the steps of the spinning process
include airflow (blow room), carding, combining, drawing, roving, and cone winding.
The final step, cone winding, is the most crucial as it decides the quality of the yarn.

Objective

The objective of the spinning process in the textile industry is to draw fibre at a mass
scale and spin it together to make a continuous thread of fibre, known as yarn. It is a
major part of the textile industry and used for manufacturing various textile fibres.
The different types of spinners used in the textile industry are Ring, Rotor and Air-jet
spinners.

Scope

A spinning mill opened raw cotton bales and cleaned the cotton in the blowing room.
The cotton staples are carded into lap and straightened and drawn into roving which
is spun using either a mule or ring frame. The yarn can be doubled and processed
into thread, or prepared for weaving. Since the profit margin is on average about 3
percent of sales turnover a very high spindle utilisation is of vital important to
profitability.Boasting at least one-third of the textile business in the country, with
2,032 spinning mills (total mills in India: 3,542), 5.63 lakh powerlooms (India: 24.86
lakh), 1.55 lakh handlooms (India: 23.77 lakh), and nearly 15,000 garment units
(close to one lakh units nationally), Tamil Nadu is regarded as numero uno in textiles
and garments. It also supplies to global brands.
 CHAPTER II

ORGANIZATION PROFILE

ARUNA TEXTILES

The association was incorporated in 2007. The main objective of the association is to
encourage friendly feeling and unanimity among textiles. Owners on all subjects
connected with their common interest next to promote and protect the trade,
commerce and manufactures of Tamil Nadu in general and of the cotton trade in
particular.

Organizational Profile And Chart

Company Name ARUNA TEXTILES

Year of Establishment

Managing Director Mr. Somasundaram

Address

GSTIN No

Phone Number

Initial Capital

Number of Workers

Auditor

Nature of Business

Email id
 CHAPTER III

SPINNING PROCESS

Converting fiber such as cotton, wool, and jute into yarn using textile machines is
called the spinning process. There are different spinning processes for various raw
materials. Here are the crucial steps involved in yarn spinning.

Blending (Blow Room)

It is the preparation step of the spinning process. The raw material comes as bale. In
this step, the bale is cleaned and mixed using a blending machine, and later airflow
is used to maintain the fiber uniformity.
Carding
Carding is where the yarn spinning truly begins. The blended bale is detangled,
cleaned, and intermixed many times to produce lays—a sheet of fibers of the same
thickness using various mechanical steps. Further, the lays are condensed to create
a web of thread known as silver.

Combining
In combining or combing, the silver is kept parallel to each other, and short-length
fibers are combed out. Combining is vital to ensure fiber strength and quality.
Drawing
The drawing or draw frame process makes silver thinner for yarn preparation. The
drawing is done using a gilling machine. Depending on the fabric requirements,
drafting is repeated to produce drawn silver.
Roving
Roving, also known as ring frame, is used to reduce the size of drawn silver so that
the yarn can spin easily. A slight twist is added that helps in roving down and up.

Cone Winding
The last step of the spinning process is cone winding. This process is the bridge
between yarn creation and fabric manufacturing. The yarn is packaged and made
ready for the next steps, such as dyeing, weaving, and garment production.
 CHAPTER IV

PROCEDURES AND METHODS OF SPINNING

The main function of purchase department is to get raw materials to produce

polyester and cotton.It also stores materials to meet the fluctuations in
price.Purchasing function includes purchase of machinery,spares and tools etc.,

Purchase Procedure

Purchase Procedure When any raw material is required, the storekeeper will give
specifications with samples of the item they need with quality and quantity. The
purchase is made only after receiving indent slips from the using department and is
approved by the manager. The purchase officer will call for quotations from various
manufacturers and suppliers. As soon as they receive the quotation the person who
is in charge of purchase analyzes the samples, quality, price, time, and they will
place an order as soon as possible.

The chairman takes charge of the finalization of raw material to be purchased. Raw
materials are purchased as a unique variety based on the hands of experience of the
chairman. The sample is first and tested to place the actual order. The cotton comes
in bales or in bores the bale weights from 170 kg to 190kg. The weight of the cotton
is calculated. The covering may weigh from 2kg to 5kg that is deducted to get the
actual weight of the cotton.

The inspector from the quality control department analyzes the moisture in the bale
by using the moisture analyzer. If it is below 8.5 then it is given for further
processing. The cotton is purchased directly from the seller and sometimes the
purchase is made through the agent. Cotton is purchased from various places like
Madhya Pradesh, Karnataka and Andhra Pradesh.

Purchase Record

● Basic samples collection

● Offer samples test result note
 ● Purchase confirmation register
● Vendor valuation record

Cotton Issue

Upon the arrival of cotton, the cotton clerk verifies the commercial document against
the purchase confirmation details in a report of cotton variety, price and number of
bales. The bales arrived, are properly identified with all the details like the party
name and lot number. This is recorded in the inward note. The weights are checked
and are recorded in the lot weight record. This weight is verified against the weight
list of the vendor. The chairman solves the discrepancy.

Production Department

The main objective of production management is to produce goods and services of

the right quality, right quantity, at the right time and at minimum cost. It also tries to
improve the efficiency.

Trial Production

The trial production is carried out for confirming the requirements of the customer.
This is being tested in the quality control department and necessary changes are
made as per the requirement. The production manager is responsible for maintaining
the production plan and he controls it with the coordination of all the department
personnel.

The Production Process

The factory manager can execute the quality plan by correcting all the mistakes and
making necessary adjustments. He fixes the speed of the machine depending upon
the count which is to be produced. Any breakdown which occurred during the
production process has been properly recorded. The shift supervisors check the
relative humidity. This is to be maintained at a certain level to get proper count.
Compliance of quality plan in accordance with mill standard is prepared on
continuous market feedback. The factory manager guides the supervisors.
One-day production of the company is 450 kg of cotton yarns, weekly 2500kg of
yarns, and monthly 7000 kg of yarns. They use the teeth, pointer and wheel based
on the count.

Product Process

Flow chart
Mixing Process
Cotton is purchased from various places all over Tamil Nadu and other states based
on the yarn count mixing. Here raw cotton and viscose staple fiber and polyester
staple fiber are properly mixed.

Blowroom

Blow room is a process where the raw cotton is processed to remove the unwanted
dusts and the seed dusts, mud etc. from the cotton passes through various stages
like Mixing, Step Cleaner, Fine Cleaners, Bale Opener, Pre-cleaner. The production
of the blow room is recorded in a slip and they are stuck on the laps they are made.

● Opening Machine
● Cleaning Machine
● Blending Machine
● Dust Removing Machine

Carding

The lap from the blow room is fed into the carding machine. The cotton is further
cleaned and it comes out in the pipe shape called a sliver. The lap fed in should be
in a proper form. There shouldn’t be any overlapping of the lap 6.5% waste should
come out in this process. The objective of carding is to remove and other waste from
cotton.

Drawing

The sliver is received from carding into this process. Eight such drums will be fed
and they come out as a single one. This process is to make the sliver to get the
uniformity.

Simplex

The yarn is stiffened in this process. The thickness of the sliver is reduced by
drafting 10-20 times and is twisted and wound up in the bobbins. The unit is using
240 spindles for the simplex. The production depends on the spindle speed. The
factory manager sets speed. It improves.

Spinning
Production depends on spinning. As every process is made aiming most important
and final the bobbins are the inputs and the final output is the cotton yarn in the
required count twist per inch. In this unit, they are using spinning frames of 440’s
spindles and totally ‘14’ frames are engaged on the production.

Cone Winding

The yarn from the ring frame cops is wound on the cone suitable for marketing. In
this process the fault during the spinning is corrected to suit the proper counts. This
step defines the quality of the yarn and, eventually, the quality of the end product.
Hence, the team responsible for cone winding must do their job with due diligence. In
this process, ring cops are used to make cone packages which are further used in
textile and apparel manufacturing.

In a competitive world, a small mistake in packaging can cost a lot. The cone winding
stage is the last stage when bad materials are identified and either corrected or
withdrawn, depending on the amount of damage. Customers want quality, and if
there is any lapse in packaging, it can negatively impact an existing business
relationship. If it happens with a well-known brand, the cost can be much more
severe.

There are many expectations from the winding processes. The packaging has to be
as per requirement, and there should be no compromise with the quality. However,
the three key objectives and demands from the cone winding step are:

1. Scan and remove faults from the yarn. Such defects are called scan-cuts.
2. Remove yarn knots and bad pieces by auto-splicing yarns.
3. Build packages that assist high-speed warping and weaving as per the
desired dimensions.

The cone winding stage can only be called a success if it meets both the quantitative
and qualitative aspects. All the functions of winding machines help in meeting these
demands. The quality can be checked by doing online and offline testing.

Quality Aspects of Winding Process

Yarn and packaging have to be fault-free. The critical criteria for measuring quality
are cone weight, cone length, and cone density. People supervising the cone
winding process must look out for the following defects that can impact the quality of
packaging:

● Missing tail end

● Wrinkles
● Double or missing ends
● Stitch
● Cut cone
● Extra hard cone
● Soft cone
● Stain
● Cone rings
● Drum lapse
● Patterning

The yarn quality depends on five parameters: Bobbin to Cone increase in U%

(unevenness percentage) and IPI value, classimat faults, rewinding faults, knotless
yarn, and yarn friction. Below are the acceptable deterioration values.

● Unevenness percentage (U%) between 3 to 5%

● Thin places can be up to 0.5%
● Thick places could be between 15 to 20%
● Neps could be between 5 to 10%
● Hairiness levels between 25 to 30%

Irregularities beyond these acceptable limits can cause significant issues in the
textile material and lead to rejection, causing losses.

Quantity Aspects of Winding Process

Textile manufacturing thrives on high-speed textile development. The focus in the

winding process is always to increase productivity and produce less hard waste to
generate maximum value and profit. Many factors determine productivity, such as,
 ● Winding speed
● Cycling
● Repeater
● Suction failure
● Splice failure
● Bobbin quality
● Winding cuts
● Loop gate functioning

The textile companies that can successfully meet the winding process' quality and
quantity demands can expect to survive in today's competitive market. Hence, the
various factors mentioned above play a crucial role in managing these demands and
generating high-quality fabrics. Any faulty cones should be removed during an
inspection and managed accordingly.

Managing Faulty Cones

Cone winding is not limited to quality checks and the elimination of faulty yarns. It
would be best if you also decided what to do with defective windings. Depending on
the level of fault, a spinner can:

1. Rewind it: If the cost associated is manageable, the fault can be removed by
rewinding.
2. Keep it: If the fault is negligible, rewinding can further damage the fabric.
3. Degrade it: It's a financial loss when the faulty cone is degraded to a lower
level but not removed.
4. Remove it: If no other option is feasible, defective yarn is removed from the
packaging, causing financial losses.

Maintaining Cone Winding Process

The spinner managing the cone winding process must take care of the following
points to ensure a better quality of yarn production.

● The winding speed must be around 1200 meters per minute.

 ● The spinners should monitor the rotation of the wax roller regularly.
● The yarn length per chase should be approximately 3.5 to 5.5 meters.
● The bobbin hardness must be in the range of 50° to 55°.
● The top and bottom clearances should be around 10 mm.
● Back winding coils should be between 1.5 to 2.5, and the length should not
exceed 80 centimeters.
● The splice strength should be at least 75% of yarn strength.
● Appropriate cleanliness must be maintained, especially while using wax
rollers and attachments.

Packing

The final stage is packing of finished products so as to protect goods from damages.
As per the customer’s instructions, packages are carried out. In packing,

1 bag = 40 cones

1 cone = 1.25 kgs

1 bag = 50 kgs

Waste Management

Waste Details

Some amount of waste is discharged at every stage of production. In order to

optimize productivity, cost and quality it is always necessary to maintain wastage at
a particular level which in turn depends upon the cotton. The waste can be classified
under two different heads.

● Auto cone winding

● Manual cone winding

Hard Waste
Hard waste includes all the waste that comes from the process such as Spinning,
Cone Winding, Double winder (DRT), Doubling, Reeling, etc. These wastes can't be
re- used in production but can be sold out. Therefore, they are called salable waste.
They are usually sold at very low cost.

Quality Control Department

The control section normally has two separate sections: one for testing the product
quality at different stages of production and also of final product, normally termed as
inspection and testing, and the second one for studying the process, normally called
as process control studies. Quality is a measurement system that covers the entire
organization from sales through shipping. Quality control is a procedure or set of
procedures intended to ensure that a manufactured product or performed service
adheres to a defined set of quality criteria or meets the requirements of the client or
customer.

● Quality planning
● Quality control
● Quality assurance
● Quality improvement

Inspection And Testing

The inspector takes the study daily in all the departments. They check the quality of
the product at each point. The report is submitted to the factory manager and the
supervisor. Reports given by Quality Control department are

● Daily production statement signed by managing director

● Daily yarn quality statement
● Daily electrical statement
● Delivery inspection report

Types of Test

● Process capability test

 ● Process capability test for manual winding
● Blow room lap chart

CHAPTER V

DEPARTMENT AND ITS FUNCTIONS

Marketing Department

Marketing is a human activity directed at satisfying needs and wants through an

exchange process. The aim of marketing is to make sales in order to earn
reasonable profit for the producer. In this organization,they are marketing the two
varieties of yarn as 40 and 30 based on their thickness. The 40 is used for making
shirts and 60 are used for making pants. In Leeds textile, the manager directly deals
with the other nearby buyers. So the marketing department is not done in full effort.
Marketing has an intensive position in today’s business activities.

Marketing of products helps in gaining popularity and profits easily.

● To market the product’s enquiry is the important step. And to enquire about
the product's quality, price, etc.
● For the party's interest, instructions were sent to the weaving section to finish
the goods within time. So, a performa invoice is used for getting payment.
● Marketing is the heart of all industrial activities. It is of vital importance for all
businessmen to understand the role of marketing in the economic
development of a country and raising the standard of living of people.

Flow Chart
4P’s of Marketing

Product : 36 & 40 warp yarn

Price : Cost of Raw Materials + Cost of Labour + Profit Margin Based on demand

Place : Erode, Somanur, Coimbatore, Palladam, Tiruppur

Promotion : Direct Marketing

Functions

● They find the market through their agents.

● Agents help in marketing products internationally.
● Sales are made based on the orders received.

Sales Department

Production of goods is done for sales. Sales mean transfer of goods from one
person to another in the course of business for cash, deferred payment or valuable
consideration. The effectiveness of sales in the organization is the most important
factor for the progress of the firm, because the final figure ultimately depends on the
efficiency of the department. The product yarn is sold through its own depots and
agencies. Each mill has its own agency. ARUNA TEXTILES also has agents in
Mumbai,Andhra pradesh and Madhya Pradesh. The produced yarn is sent to
Agencies. The Agency takes the work of sales activities. 75% of the yarn sales are
made through the agency in other states and the rest 25% sales are made by the
local agents.

Objectives

● To get customers to maintain their purpose of the product.

● They also should build a relationship between the company and their clients.

Explanation Of Process

● For performing sales activities of the company, the company is appointing

selling agents all over Tamil Nadu to cover all customers.
● The agent of the company is Mr. Rajesh to sell the products all over Tamil
Nadu. The selling agent will collect, enquire and forward the same for
attention and approval of general manager marketing.
● Production of goods is done for sales. Sales mean transfer of goods from one
person to another in the course of business for cash, deferred payment or
valuable consideration.

Stores Department

Most of the company failures are due to locking up huge amounts of funds in stock.
Either overstocking or under stock both are not worthwhile to a company. Hence,
maintenance of optimal stock does not result in shortage of working capital.
Storekeeper has to maintain the complete list of raw material and peripheral
suppliers along with their price list to contact them immediately during emergency
circumstances. Similarly, the gatekeeper should not allow anyone to carry goods
outside the company without receiving the permission from the store keeper.
Storekeeper has to decide the minimum and maximum quantity of materials to be
stored in the godown. After receiving the goods, it is the duty of the storekeeper to
ascertain or verify that the goods received match with the specification mentioned. If
there are any deviations, the storekeeper should receive the explanations for the
same from the supplier. If the explanations are not satisfactory, then the storekeeper
should return the goods once again to the supplier.
Functions Of The Store Keeper

● The storekeeper is in charge of all the goods which are under his control.
● Storekeeper has to maintain all records relating to materials inwards and
materials outward

In godown, raw materials (cotton) and the waste cottons are stored. In the newly
purchased cotton, the total waste is 10 percent; out of this waste five percent is
reused. Eight percent of polyester extra wastes are sold to other mills once in three
months. The waste processed in the machinery is converted into cotton and the
converted cotton is used for mixing. The newly produced textile is tested in a central
testing lab. When this textile is sold sales tax is levied.

Ordinary Purchase

In ordinary purchases, the store's keeper knows about the scarcity of material in the
stores and he places the order for those materials. Purchase is made by the
purchase clerk.

Emergency Purchase Materials like wheels etc. Becomes important and they have to
purchase it immediately. This comes under the category of emergency purchase.
The storekeepers after receiving the intent of the spinning supervisors approach the
parties and purchase those materials. No materials are warded and taken out
without the consent of the store keeper. If a material enters the gate, it is properly
checked by the store keeper and the security guard and then they are received by
the stores department.

Accounts Department

Accounts are important for every company. The Accounts department provides
authorization and control to all other subsystems to utilize money more effectively
through a well-designed mechanism. The Accounts department is headed by the
Finance Manager (finance and accounts) and his team of efficient accountants. They
maintain records for each and every transaction relating to business. All the financial
decisions taken are reviewed by the managing director before being put into action.
This department is in charge of all the tax computation involved with any local
purchase and sales made. The financial year of the company starts from 1st of April
and ends 31st of March every year. The accounts department also computes the
weekly wages and monthly salaries for the employees of the company.

Functions Of Accounting Department

Payroll and Monitoring Employees' : The payroll function of an accounting

department ensures that the organization pays its employees accurately, including
bonuses, commissions and benefits. The department monitors employees' time off,
vacation and sick days. It pays the government taxes as well as union dues and
other withholding from an employee's paycheck.

Inventory Cost Management: A company's inventory is the goods owned for the
purpose of sale. Inventory is usually sold within a year. An accounting department
watches the cost of inventory over a specific period against its revenues to ensure
that the cost of raw materials, labor and overhead do not negatively impact cash
flow.

Recording Fixed Assets: In order to function effectively, a company may need

machinery, equipment, vehicles and other fixed assets it uses over several years.
The accounting department is responsible for recording fixed assets on a balance
sheet with depreciation.

DETAILS OF WORKERS

BLUE COLLAR JOB NUMBER OF WORKERS

Male (For three shifts) 15

Female (For three shifts) 5

Total Labours (For three shifts) 20

Safety

● Fire safety equipment

 ● Nursing staffs
● First Aid boxes
● Emergency vehicles

Accounts Classification

● Audit fees
● Bank charges
● Bank
● Canteen maintenance
● EB lighting charges
● Factory maintenance
● Electrical repairs
● Provident fund collection and payment

Trial Balance

A trial balance is a list of all the general ledger accounts (both revenue and capital)
contained in the ledger of a business. This list will contain the name of each nominal
ledger account and the value of that nominal ledger balance. Each nominal ledger
account will hold either a debit balance or a credit balance.

Trading And Profit & Loss Account

The preparation of this account is possible only after the preparation of the trial
balance. At the end of every year the final account is prepared to know whether the
company is making profit or loss, during the year.

Balance Sheet

This is prepared to know the accurate financial position of the company. This
statement sets out the assets and liabilities of the company Balance sheet and profit
& loss are prepared and the statements are audited by auditors.

In Concern With Bank Accounts,

Payment voucher provides the details like Bill No. requested date etc. for the
payment of the cheque is prepared as requested by the department. Monthly
account statements end by bank are cross-verified. After the receipt of challan,
payment is recorded, projection balance sheet is prepared.

Software used in this concern is Tally Prime, ERP software for production.

Personnel department

The personnel department is responsible for those aspects which are primarily
concerned with the relationship of management employees and with development of
the individual and group. Aruna Textiles has exceptionally established the way of
harmony and handshake with the employees. Fair and fabulous working
environment enables the workers to do their work more enthusiastically. Monthly and
weekly wages are available based on their preference. No labor union exists in
Aruna Textiles Training Of Workers Training is done in a very excellent manner, as
a huge percentage of workers are apprentices; the personnel manager just gives
instruction to the workers and the supervisors give the training.

Recruitment

Recruitment is by direct approach of the workers or direct visit to the work place and
the contract agency also helps the mill for recruiting. They are paid with the
commission for the same.

Total Quality Management

The total quality of the product is maintained through

● Housekeeping
● Healthy working environment

Time Office

● It is the duty of timekeeper to maintain the time of entry and exit of each and
every worker/employee.
● Working times of labour are divided into three shifts such as 1st shift, 2nd
shift and 3rd shift.

SHIFT SHIFT TIMING HOURS

1st shift Day shift 7:30 a.m. to 3:30 8
p.m.

2nd shift Half night shift 3:30 p.m. to 11:30 8

p.m

3rd shift Full night shift 11:30 p.m. to 7:30 8

a.m

4th shift General shift 7:45 a.m. to 5:30 9.45

p.m.

Time Office Performs The Following Functions

● Verifying the daily working employees in mill

● Mill is using purchasing cards for the above calculation.
● To provide overtime work to workers, if work is more.

Workers details

WHITE COLLAR JOBS NUMBERS

Factory Manager One

Technical Manager One

Personal officer/Assistant One

General Supervisor One

Shift supervisor Two

Office Staff One

Quality Checking staff Two

Watchman/Security One

Employee State Insurance

ESI benefit is given to permanent workers. It is a self-financing social security and
health insurance scheme for Indian workers. This fund is managed by the
Employee’s State Insurance Corporation (ESIC) according to rules and regulations
stipulated there in the ESI Act 1948.

Wages And Salary

All operative workers except casual are paid monthly wages. The employees get
type leave. If any employee is sick he will get 60% of daily wages. If he goes on an
accident leave, he will get 90% wages.

Bonus

Last Diwali, the employees got a bonus of 10% minimum. If the mill earns surplus
profits, the percentage of bonus paid will be increased.

Provident Fund (Pf)

It is the form of social safety net into which workers must contribute a percentage
from their salary and the company also contributes a percentage as PF to their
workers.

Canteen Facility

Canteen facility is available to workers and staff. Canteen slips/tokens are given to
them to get lunch, tea, etc.

Safety Measures

The administration takes great care about the safety of the workers. The mill
provides a number of firebuckets in each department.

Refreshments

The company provides refreshment facilities during night shifts to the workers. It also
provides tea/coffee 2 times during the office hours to the office staff and workers.

First Aid Facilities

The company provides the first aid facilities to the employees by means of providing
the first aid boxes and other timely help to all the departments.
 CHAPTER VI

CONCLUSION

A good textile product comes from the spinning process, specifically winding. The
quality is not limited to the product; it also means maintainability, reliability,
production, and financial viability. Hence, the idea of quality may be different for
different customers and has to be dealt with effectively.Finding partners who can
spin yarns or finding out industry-standard parameters and trends can be
challenging.Apart from connecting with key stakeholders in the industry, including
manufacturers and suppliers, able to find excellent insights into how the new-age
textile industry works.