PRODUCTION DEPARTMENT The function of this department is very much important. This department is headed by the production Manager.

Under this unit manager, Supervisors, workers are working. The main important aspects of this department are to ensure about the quality assurance of the each product that were making at their own premises. Production is the bigger picture of various functions that affect the overall process and quality of an organizations service or manufacturing. The production management deals with processes, resource allocation, and quality to run the business day to day in an efficient and effective manner production management techniques are used in both manufacturing and service industries. The production manager are responsible for managing both physical materials doing a wonderful job to make their effort worthfulness.

OBJECTIVES OF PRODUCTION DEPARTMENT

Production is an organized activity in a manufacturing organization. Each organized activity must spell out its objectives so that its existence can be justified on the basis of the degree of attainment of these objectives. 1. The unit cast of the product should be estimated carefully and efforts should be made to stick to the cost standards. 2. The industrys production department should take utmost care in maintaining quality levels. 3. Setting of proper manufacturing quality levels. 4. Setting of proper manufacturing schedules to ensure time lines. 5. Optimum utilization of inputs of production like men, material and machines. PRODUCTION PROFILE AND ITS PROCESS. PRODUCTION MANAGER

SUPERVISOR

OTHER STAFFS

ARTISANS

The supply of cotton to the Kerala Khadi and Village Industries Association is mainly from the cotton growers co-operative Society in Pollachi and Thripura in Taminadu. This cotton is processed at KVIC Central Silver Plant at Kuttor and silver roving supplied to Khadi institutions. However, cotton for NMC ( Non Metric Charka) 50 count is processed at Avinissery silver unit of Kerala Khadi and village Industry Association for other societies, silvers are supplied by KVIC Kuttur. Association is also purchasing silvers from KVIC Kuttur directly. Silver are converted in to yarn by spinners of the association and spinners of other societies. Kerala Khadi and village industries association have a mini warping unit at Avinissery. However this unit is not able to meet the warp requirements fully chemicals for the dying unit are brought mainly from Kannur and bleaching of cloth is done in the Avinissery complex. PRODUCTION PROCESS There are two main processes in production of Khadi. They are Spinning Weaving Spinning Spinning process includes cleaning of cotton, lap making and making ravings/ silvers. These silvers are then converted in to yarn. Weaving In weaving there are two motions, primary potions and secondary motions. Primary motions include shedding, picking and beating motions are performed in successions, which are in total called as weaving. Secondary motions are let off of warp and taken up of cloth. For every insertion of the pick, the cloth length grown up. The cloth woven is wound on the cloth roller continuously or immediately to keep the fall of the cloth in constant position. This called take up of cloth. The preparatory processes chiefly employed for the warp may be classified into winding, warping, sizing and looming.

a) Winding This is the process of connecting the yarn from one packages form to other convenient package form. The object of this process is to convert the packages containing less length yarn in to packages longer length yarn. Normally for the Khadi industry, the yarn is received in the form spinning mills and converted in the form of bobbin / cone / cheese winding machines.

b) Warping In the warping process, the individual yarn form the longer length packages combined and drawn together as a sheet containing certain number of threads of definite length. The individual thread in the warp sheet is called ENO. The sheet of warp is either converted in to ball form or directly wound on to another packages called warp beam as per the next sequence of process. c) Sizing Sizing is the most important process in the preparatory sequence while weaving lave yarn is subject to more stress and strain than weft yarn. Hence yarn used in warp should have more strength than the weft. If folded yarn is used in warp, there is no necessity of sizing because folded yarn has got more strength than the single yarn. When single yarn is used in wrap, it is most to size it to make smoother, round, stronger yarn. For the khadi industry, sizing is carried in the yarn or bank or wrap sheet form. d) Looming The end from the wrap beam is either joined with old wrap by twisting I knotting of old draft is continued or it is passed through the heated and reed of the loom if the new draft is required. The operation is called Drafting and Denting respectively. Then the wrap sheet kept in proper alignment and tension between wrap beam and cloth by the process called gaiting. Now the wrap is ready in the loom for weaving.

Weaving When a fabric containing size is received at the gye house the through removal of size is essential to make the fabric easily and completely wet. During scouring and bleaching which are regular features of the processing, the size cannot be removed. The presence of size in the fabric reduces the efficiency of the subsequent purification processes and hinders the dying apart from making the material water impermeable. Hence resizing process in very important with cotton fabrics. As the dying activity is to be undertaken on a very pollution can be assessed only when the dying unit becomes operational. Processing at street weaver level Spinners get readymade silvers. This silver is converted into hanks and hanks are supplied to the society The yarn hanks are first socked in water for 2 days and stumped to remove the yellowness / impurities from the yarn. This process is repeated for few days. Some of the weavers boil the yarn in water to quicken the process of soaking. Then the yarn is dries and run on the warping machine for definite length and number of threads and sizing is done with starch outside the worksheet (street warping). The preparatory work is either done by the

weaver in the area a job work basis. The whole process takes 7 8 days. The prepared warp is then knotted (jointing). After weaving, the final product is taken to the society.

Machinery / Equipment / Loom Charka There is different type of charkas used for spinning viz 6 spindles, 8 spindles. Looms Mostly frame looms are in operation in the organization. In the case of Kuppadam, a single design box (pettu) is used. Frame loom A loom with all the required accessories kept together is a frame. Normally this loom will be place on the ground without any fittings or foundation bolt. The loom remains stable on the variety of cloth to be woven. The loom will have a rest, slay, and head to sit. In most cases the loom is used to weave coarser verities of fabric. Product Line A product line is an expression used to describe a group of closely related products. It is a part of the product strategy to determine whether an organization will have a single product or more than one product. It is a group of products that are related in the same way be being alternatives to fulfilling the same customer need by being marketed to the same target markets on through the same distribution network or by being in common price category. A product line is able to satisfy a class of need to be used together to be sold to the same customer groups, to be moved through the same distribution channels or fall within given price changes. The product line of khadi industry include Muslin Khadi, Medium Khadi, polyvastra, silk, weaving machinery, new model charka-muslin and poly thread, cane furniture, honey, soarp, oil. Types of Products The Khadi and village industry (K. V. I.) sector products a wide range of exclusive products, which are having distinct characteristics. These products are as under. (A) Khadi Handspun and hand woven khadi is very comfortable to wear compared to the artificially made synthetic fibers like Nylon, Rayon and Terylen etc. The products are cotton, woolen, silk and polyvastra khadi. Cotton khadi is 100% of cotton, which was a great demand abroad, and it is available in different shades and colours. Attractive readymade garments are being designed in the form of Kurta paijama, shirt, ghagra, choli, salvar kammis and other attractive garments.

Types of Khadi. (i) Cotton Khadi:It is one of the types of Khadi, which include 100% of cotton. Dhothies. Lungies, towels, shawls etc are included in this category. (ii) Silk Khadi :Silk khadi comes in various categories like tussar, matka etc.Silk khadi can be converted into shirting, into attractive saris with sari boarder or printed sari such as balucuchari saris, which has rich embroidery or Kanjeepuram with its intricate designs woven in silver or golden. (iii)Woolen Khadi :Woolen khadi items consisting of sweaters, mufflers, blankets and socks. (iv) Polyvastra khadi :Polyvastra hadi consisting of shirting and suiting in attractive shades and designs including dress materials and saris. (v) Muslin Khadi This type of khadi is very thin, which comes under 90s, 150s and 100s. (B) Fiber Fiber utility items are made out of sisal banana, pineapple, palm and other fibers. Some of the products include bags, table mats, wall hanging, carpets, floor mats, floor plot, holdersets. Palm fiber products like fancy bags, baskets, mats etc. are in great demand. (C) Leather Leather products range include footwear, like Kolapury chappals, sandals, shoes, purses, brief case, jewels bags, attractive readymade garments etc. (D) Cane and bamboo Fancy utility articles by using cane and bamboo as raw materials are produced in the north eastern parts of country. The items like furniture, sofa sets, partition wall, mats, handy crafts items etc. can be supplied in bulk quantity. (E) Agarbatti Incense sticks with fragrance are available in different verities, which has good demand in India and abroad. Women workers make incense sticks. In foreign country, agarbatti is used as incense in place of artificial air purifier. (F) Processed fruit products This is one of the activities taken up by the institutions and co-operative societies and financed by the commission. Products like mango pulp, juices, chatni etc are exported in large quantity. The products are covered by FPO (Food Product Organization) license.

(G) Handmade paper This is a beautiful product which was the cloth rags and waste paper as raw material for production, thus contributing in saving the trees and hence preservation of ecology. The strengths of handmade paper are as follows; Long product life (100 years or more) Uniqueness in texture Eco friendly, does not use wood pulp as raw materials and hence save trees. Convert waste into wealth, through recycling nature. Handmade paper product range from stationary items like files, letter pads, envelops, fancy bags, visiting cards, greeting cards, watermark, certificate and decoration materials, photo album etc. There is a market for this product in particular. (H) Honey Honey is natural syrup collected y honey bees. There are two types of honey produced. One by the bees produced in forest and another apiary honey produced by installing colonies of bees and maintaining this in systematic manner. Honey is also used as cough syrup, blood purifier and as a general tonic. The honey in India is costlier than in the International market. However, this can be overcome by minimizing wastage and increasing the productivity. (I) Pottery and stone wear items Clay articles produced in rural areas by potters known a prajapaties are in great demand in the country as well as abroad. In market, fancy pottery items and terra cotta are in great demand. (J) Papad and Masalaa Papad and Masala are in great demand in India and abroad. Mahila Hriha Udyog Lijjat Papad of Khadi and Village Industry, exports papd and masala to UK, USA, Gulf Countries and Newsland. (K) Herbal products K. V. I. produce a number of herbal products like herbal shampoo, tooth powder, health tonic like Chyavana prash and Churnas.

PRODUCTION UNITS The main production units are situated at Avinissery, Choorakkatukara, Erumapetty, Kadavallur, Kodakara, Mayannur, Thrikkur, Peringottukara and Thrissur.

FUNCTIONS AND RESPONSIBILITIES OF PRODUCTION MANAGER Functions The important functions of production manager are :1. Manage and control the logistic function to ensure supplies of raw-materials, finished goods, parts and accessories are available within required time frames and budgets. 2. With the planning and controlling production manager, develop, direct the implementation of production business strategies and activities to enable the production to achieve output and quality objectives. 3. With the R & D Engineering Manager, develop, direct the research and development/engineering activities to ensure products and Techniques achieve business needs within the standard. Set by the market and the regulatory standards bodies. 4. With the warehouse and Distribution Manger, develop, direct and control the workhouse and distribution activities to ensure the efficient and economical utilization of facilities for storing and distributing the finished goods. 5. The Production Manger, develops, directs the implementation of manufacturing sustainability strategies / action plans and continues improvement programs. 6. The Production Manger must also monitor operations to ensure that planned output levels, cost levels and quality objectives are met. 7. The maintain and efficiency production process with a a workforce that can readily adapt to new equipment and schedules. Responsibilities 1. Responsible for directing the production activities to ensure the current and future plans of the organization are met. 2. Report to the Managing Director on major production issues and results. 3. Participates in group corporate planning and budgeting workshop. 4. Responsible for establishing production organization structure / management process. 5. Responsible for implementation of policies or procedures throughout the production department. 6. Responsible for recruitment / selection / orientation training of seniors personnel of the production department. 7. Responsible for purchase of capital goods / production operation equipment. 8. Responsible for production planning / budgeting 9. Responsible for cost control programs. 10. Responsible for individual relation or union negotiation 11. Responsible for building maintenance 12. Assist in creation of efficient process through hands on development and training.

PRODUCTION DEPARTMENT STRUCTURE

CHAIRMAN VICE CHAIRMAN SECRETARY PRODUCTION MANAGER

UNIT MANAGER
SUPERVISOR WORKERS