1

INTRODUCTION
Spinning is an ancient textile art in which plant, animal or synthetic fibers are
twisted together to form yarn. For thousands of years, fiber was spun by hand using simple tools,
the spindle and distaff. Only in the High Middle Ages did the spinning wheel increase the output
of individual spinners, and mass-production only arose in the 18th century with the beginnings of
the Industrial Revolution. Hand-spinning remains a popular handicraft.
The Spinning is a technological system in which twist is inserted to the fibers and
yarn is produced. The spinning process includes many processes which transform the bales of
raw cotton into a yarn ready for weaving. The term "spinning" can refer to the whole activity or
just to the final process of making the yarn. The raw cotton arrives in the form of large bales.
These are broken open and a worker feeds the cotton into a machine called a "breaker" which
gets rid of some of the dirt. The cotton may not be consistent in quality from bale to bale
therefore samples are taken before getting bales in best quality.
Natural fiberscotton, flax, silk, and woolrepresent the major fibers available
to ancient civilizations. The earliest known samples of yarn and fabric of any kind were found
near Robenhausen, Switzerland, where bundles of flax fibers and yarns and fragments of plain-
weave linen fabric, were estimated to be about 7,000 years old.
Cotton has also been cultivated and used to make fabrics for at least 7,000 years.
It may have existed in Egypt as early as 12,000 B.C. Fragments of cotton fabrics have been
found by archeologists in Mexico (from 3500 B.C. )., in India (3000 B.C. ), in Peru (2500 B.C. ),
and in the southwestern United States (500 B.C. ). Cotton did not achieve commercial
importance in Europe until after the colonization of the New World. Silk culture remained a
specialty of the Chinese from its beginnings (2600 B.C.) until the sixth century, when silkworms
were first raised in the Byzantine Empire.
Synthetic fibers did not appear until much later. The first synthetic, rayon, made
from cotton or wood fibers, was developed in 1891, but not commercially produced until 1911.
Almost a half a century later, nylon was invented, followed by the various forms of polyester.
Synthetic fibers reduced the world demand for natural fibers and expanded applications.
Until about 1300, yarn was spun on the spindle and whorl. A spindle is a rounded
stick with tapered ends to which the fibers are attached and twisted; a whorl is a weight attached
to the spindle that acts as a flywheel to keep the spindle rotating.
2

The fibers were pulled by hand from a bundle of carded fibers tied to a stick
called a distaff. In hand carding, fibers are placed between two boards covered with leather,
through which protrude fine wire hooks that catch the fibers as one board is pulled gently across
the other.
The spindle, which hangs from the fibers, twists the fibers as it rotates downward,
and spins a length of yarn as it pulls away from the fiber bundle. When the spindle reaches the
floor, the spinner winds the yarn around the spindle to secure it and then starts the process again.
This is continued until all of the fiber is spun or until the spindle is full.
The fibers used in the textiles industry as raw material could be broadly classified
into:
1. natural fibers.
2. Man made fibers.
The natural fibers could be grouped into
a. Vegetable cotton, jute, etc.
b. Animal (Silk and Wool), and,
c. Mineral (Gold, Silver Aluminum etc.)
Man-made fibers could be broadly categorized into:
i. Degenerated, and,
ii. Synthetic Fibers.
Among the degenerated fibers, there protein fivers (cess in, alginate etc.) and
cellulosic fibers (viscose, poly nosic etc.) the category of the synthetic man/made/fivers included
polyester, polyamide and acrylic etc.
Cotton is the most widely used textiles fiber today. After the cotton crop is
harvested the kapas has to be ginned in order to separate fiber from the seeds. After ginning, the
cotton is available in a loose opened form. For convenience of handling and transposition, cotton
3

is compressed and packed into bales. The quality of cotton is judge in terms of its Grade and
Staple.
The grading of cotton done with reference to impurities such as leaves, sand, dust,
broken, seeds naps, moles and color of cotton. But the fiber properties of cotton are judged
mainly by the length of the fiber i.e. the Staple length. Quality of cotton depends on its physical
properties viz. length, fitness, strength and maturity by etc.
India Spinning Industry has gone from strength to strength since a very long time
now as it was the hub of cotton manufacturing. Cotton is not only consumed to the highest extent
in India but it has also become one of the most profitable textiles in the export industry. Spinning
in India can be classified into 2 categories: medium and long staple. But there was a shortfall in
the 'extra-long' category that continued for many years. There was a massive downfall in the
cotton spinning in India during 2004-2005. The production rate of cotton was about 4 lakh bales
that was less by 5 lakh bales from the required rate which was 9 lakh bales. Mr. P. D. Patodia,
the Chairman of the Standing Committee on Cotton, CITI-CDRA said that the manufacturing of
cotton will rise to 11-12 lakh bales in 2010.
The present downfall in the cotton production has witnessed a 50% increase in the
price of Indian varieties of ELS, which is detrimental for the spinning industry in India. Spinning
mills require domestic accessibility of ELS cotton in increased quantity and of better fiber
qualities.
Advantages of Training
There are many advantages in conducting training, They are:
Man Power Development.
High Morale.
Higher Performance.
Uniformity of Procedures and increased
Economy of Materials and Equipment.
Results in less supervision.
4

Scope of Training
The trainees learn on the actual equipments in use and in the true environment
of the job.
The trainees learns rules and regulations, procedures by observing their day to
day operations in the company.
This type of training can increase knowledge with skill in short period.

Objectives of the training
To study about the production process.
To know about the organizational structure.
To know about the various department activities.
To improve the personal skills & management skills of the trainee.
To observe the working methods of KUMAR TEXTILES PRIVATE LTD., Industry.

Limitations of the training
A good manager of the organization is not willing to provide the necessary
support to carry out the training.
In some departments the workers did not share the necessary information.
The main objective of training is get first-hand knowledge of the organization
but the trainers are not permitted to take any problem for this study.




5

INDUSTRY PROFILE
The textile industry is a term used for industries primarily concerned with the
design or manufacture of clothing as well as the distribution and use of textiles. Prior to the
manufacturing processes being mechanized, textiles were produced in the home, and excess sold
for extra money. Most cloth was made from either cotton or flax, depending on the era and
location. By the end of the 16th century, cotton was cultivated throughout the warmer regions
in Asia and the Americas. In Roman times, wool, linen and leather clothed the European
population: the cotton of India was a curiosity that only naturalists had heard of, and silk,
imported along the Silk Road from China, was an extravagant luxury. The use of flax fibre in the
manufacturing of cloth in Northern Europe dates back to Neolithic times.

Cloth was produced in the home, and the excess woven cloth was sold to
merchants called clothiers who visited the village with their trains of pack-horses. Some of the
cloth was made into clothes for people living in the same area and a large amount of cloth was
exported. The process of making cloth depends slightly on the fiber being used, but there are
three main steps: preparation of fibers for spinning, spinning, and weaving or knitting.
6

The key British industry at the beginning of the 18th century was the production
of textiles made with wool from the large sheep-farming areas in the Midlands and across the
country (created as a result of land-clearance and enclosure). Handlooms and spinning
wheels were the tools of the trade of the weavers in their cottages, and this was a labour-
intensive activity providing employment throughout Britain, with major centers being the West
Country. The textile industry grew out of the industrial revolution in the 18th Century as mass
production of clothing became a mainstream industry. Starting with the flying shuttle in 1733
inventions was made to speed up the textile manufacturing process. In 1738 Lewis Paul and John
Wyatt patented the Roller Spinning machine and the flyer-and-bobbin system. Textile mills
originally got their power from water wheels, and thus had to be situated along a river. With the
invention of the steam engine, in the 1760s to 1800s, mills no longer needed to be along rivers.
By the later 20th Century, the industry in the developed world had developed a
bad reputation, often involving immigrants in illegal "sweat shops" full of people working
on textile manufacturing and sewing machines being paid less than minimum wages. This trend
has resulted due to attempts to protect existing industries which are being challenged
by developing countries in South East Asia, the Indian subcontinent and more recently, Central
America.
Whilst globalization has seen the manufacturing outsourced to overseas labor
markets, there has been a trend for the areas historically associated with the trade to shift focus to
the more white collar associated industries of fashion design, fashion modeling and retail.
India Textile Industry is one of the leading textile industries in the world. Though
was predominantly unorganized industry even a few years back, but the scenario started
changing after the economic liberalization of Indian economy in 1991. The opening up of
economy gave the much-needed thrust to the Indian textile industry, which has now successfully
become one of the largest in the world.
India textile industry largely depends upon the textile manufacturing and export.
It also plays a major role in the economy of the country. India earns about 27% of its total
foreign exchange through textile exports. Further, the textile industry of India also contributes
7

nearly 14% of the total industrial production of the country. It also contributes around 3% to the
GDP of the country. India textile industry is also the largest in the country in terms of
employment generation. It not only generates jobs in its own industry, but also opens up scopes
for the other ancillary sectors.
India textile industry currently generates employment to more than 35 million
people. It is also estimated that, the industry will generate 12 million new jobs by the year 2010.
Indian textile industry can be divided into several segments, some of which can be listed as
below:
Cotton Textiles
Silk Textiles
Woolen Textiles
Readymade Garments
Hand-crafted Textiles
Jute and Coir









8

COMPANY PROFILE
ABOUT KUMAR SPINNING MILLS
Kumar Spinning Mills Private Ltd an ISO 9001:2000 company started at the year
of 1990, a major yarn producer and manufactures. It is located at Kappalur, from Madurai. Total
area of industry is 10 acres. Only 30 percent of the area is utilized for the industry buildings.
In 1990 the Kumar Spinning Mills Private Limited has started with 3000 spindles.
The main product is Reeling yarn and Cone yarn. In early stage the yarn produced was used for
bet sheet and towels. The count of yarn spun were 20s, 30s, 2/20s. The turnover was around
rupees 2 crores per annum. The number of labours employed was 70. In 1995 the mill was
expanded the spindles with 3000 and the total spindles was 6000. The count of yarn spun were
20s, 30s, 40s, and 2/20s. The turnover was around rupees 5 crores per annum. The quality of
yarn was improved from weft to warp. The number of labours employed was 120.
In the year 2000, the mill was expanded the spindles with 4000 and the total
spindle was 10000. The turnover of the company was around Rs.5 crores per annum. The quality
of yarn was improved from warp to hosiery.
In 2003, the mill has expanded the spindles up to 12000, with latest machineries
imported from foreign countries. The counts of yarn spun were 20s, 30s, 40s, and 52s. The
turnover of the company was around Rs. 12 crores per annum. The number of labours employed
was 250. The yarn was supplied to number one brand customer like SANKU MARKS, 144,
3MANGOES, KIBS, etc.
In the year of 2005 the mill is having 15000 spindles with latest machineries
from leading machineries manufacturers. And the company gets the auto cone winding machine,
which gives quality of yarn production.
Now the year of 2010 the company only having 107 ladies and 69 men labours in
industry totally 192 workers are working in the company, because the power cut the government
9

orders to the spinning mills have only running 60 percentages of machineries and so the
company gives retirement to their employees.
There is three shift production are done in Kumar Spinning Mills Private Limited.
The shift times are as follows.
o Shift 1 working time (7am -3pm)
o Shift 2 working time (3pm -11pm)
o Shift 3 working time (11pm -7am)
CUSTOMERS
Palani mudaliyar & co.
Sri ram textiles.
Saravana fabrics.
C.S exports.
Dharshini pvt ltd.
COMPETITOR

Sri Gomathi Mills Private Limited
Ganapathy Mills Limited
Subburaj Spinning Mills Private Limited






10

VISION AND MISSION STATEMENT
Our vision:
To achieve excellence in all sectors of the textile industry, from fiber to finished product,
constantly striving to be at the forefront of our industry and to generate highest possible value for
all stakeholders.
Our mission:
To manufacture international quality yarn and fabric, with the highest level of
competitiveness on all parameters.
To effectively harness and integrate all available technology across various elements of
the textile chain.
To cater to product innovation by mastering value added areas like processing and
finishing.











11

ORGANIZATIONAL STRUCTURE



Figure 2.1
Sales
Executive
Worker
Marketing
manager
Store
Keeper
Supervisor Labor
officer
Assistant
Engineer
Worker Worker
Worker Worker
Production
manager
Purchase
manager
Engineer
Human
resource
manager
Accountant
Worker
Finance
manage
r
Board of Directors

General Manager
Quality
assurance
manager
supervisor
Worker
12

PURCHASE DEPARTMENT
Purchase is the most important and necessary department in the spinning mill. This helps to
get continuous available of raw material to the company. The purchase of cotton is estimated by
the word bale.

Purchase Procedure
Samples
For the purchase of yarn, which is the main raw material for producing cloth the company
will procure various samples from various supplier strong their representative. According to their
quality requirements, they will analyze the sample and finalize the yarn purchase.

Quotations
For the purchase of machinery, tools, parts, other than cotton they invite quotation from
various suppliers. After the quotations were received they analyze the quotations, based on the
price and quality. Finally they will finalize one quotation which is quoted low in price and of
best quality.

13

Payment to Raw Material
The company purchase raw material both by credit purchase and cash purchase. The
credit purchase will be given a time period 30 or 40 days. The time period in the case of cash
purchase is maximum four days. The purchase of packaging cones and cotton are based on the
weight and quality of the bags.

Direct Payment
The direct payment is a mode of paying money to the supplier directly. For the small
items purchased will be made on direct payment. In this type the organization will pay the
amount immediately and directly with ease, where the amount involves less money, the direct
payment is preferred.

Purchase of Stationary and Misc things
Usually the materials required by the department enter their order in computer.
Then orders placed will be shown to the purchase department, the purchase department then
checks the materials that are available in store and invite quotations if it is not available in the
store. The quotation which is low and better quality is selected and order is placed. But this
process is not suitable for small things like stationary like pen, pencil, paper, etc., and emergency
materials.

Importance of Purchases Department
Purchasing raw material to the factory without which the wheels of machines
cannot move.

Savings in material cost will increase profits in the turnover.

Material managements organizations that exist now have evolved out of

purchasing departments.



14

Store Keeper
The purchase- in charge maintains the storage details in the factory premises. The store
keeper is fully responsible for the material stored in the stores. He will maintain proper books for
every movement of materials.

Functions of Store Keeping
Receiving handling & speedy issue of materials.
To ensure regular supply of materials.
Effective utilization of store space
To keep the details of the items available in store up to date.
To provide service to the organization in most economical way.
Duties of Purchase Manager
To make purchase of reasonable quantity so as to keep investment at minimum.
To make purchases at economical price.
To purchase the proper quality of raw materials.
Samples are tested by lab assistants about the grade, stable length and
uniformity.
Finally the officer may have discussion with manager and the decision have
taken for purchase for high quality & quantity.
Procedure
Godown in-charge is the responsible person for the cotton and yarn issue. The purchased
cotton stored in godown, which will be separated under the name of its supplier. The godown in-
charge issues the cotton to the production section.
Out parties account.
Raw materials and stock account.


15

LEARNING:
I learned from this department how to purchase the raw materials from other
countries.
This department takes care of maintaining the raw materials for its production
process
This department is keen on reducing the maintenance cost of its inventory. This is
done by maintaining the optimum inventory level.
















16

PRODUCTION DEPARTMENT
Cotton which is in the form of bale is fed to blow room followed by various
operation like carding and coming depends on the requirements.
The Spinning is a technological system in which twist is inserted to the fibers and
yarn is produced. The spinning process includes many processes which transform the bales of
raw cotton into a yarn ready for weaving. The term "spinning" can refer to the whole activity or
just to the final process of making the yarn.
The spinning process is shown in the following diagram.



17

PRODUCTION PROCESS
MIXING ROOM:
In spinning mill production the first process is done on the mixing room. In this
room chemical and water will be spread over the cotton before entering the machine. In the
mixing room the function of cleaning the cotton and their seeds and dust is done. 10 to 20
percentage of cotton is cleaned at this department.

Mixing of cotton brought to make a uniform blend in order to make a uniform
yarn with high quality parameter in order to avoid any shade problem. For this purpose, the
number of bales is mixed to get uniform results. Raw cotton is purchased from best Cotton
growing areas of country and also cotton bales are imported from foreign countries. For stocking
and mixing, sandwich-mixing technique is used.
BLOW ROOM:
At blow room more than 80 percent of dust and seeds are removed. The cylinder
form of cotton is made i.e. 50 to 60 meters lap. A lap is a sheet of cotton fleece rolled around an
18

iron rod inserted in the lap spindle. When the full lap is removed from the sketchers, the spindle
is pulled out and the lap remains around the iron rod.


CARDING:
This process is the Heart of the Mill where converting the cylinder type cotton
into sliver form is done. The opened fibers are collected by the doffer comb or the doff roller in
the form of a web. This web is then passed through the trumpet to give it the shape of a rope and
coiled inside a can by means of a coiler. The rope form of cotton material is called a sliver.
The card is the most important machine in the yarn manufacturing process.
It performs second- and final-level cleaning functions in an overwhelming majority of cotton
textile mills. The card is composed of a system of three wire-covered cylinders and a series of
flat, wire-covered bars that successively work small clumps and tufts of fibres into a high degree
of separation or openness, remove a very high percentage of Trash and other foreign matter,
collect the fibres into a rope-like form called a sliver and deliver this sliver in a container for
use in the subsequent process.
19



COMBING:
Combing is a technique that has been used in the preparation of textiles for
centuries. Essentially, combing is a process that helps to smooth and prepare fibers for use
in spinning. Combing also helps to separate short fibers from longer ones, which also helps to
make the process of spinning much easier. The combed cotton will feel smoother to the touch,
and also produce a garment that will wear longer than a garment made with uncombed cotton.
A small number of mills produce combed yarn, the cleanest and most uniform
cotton yarn. Combing provides more extensive cleaning than is provided by the card. The
purpose of combing is to remove short fibres, neps and trash so that the resulting sliver is very
clean and lustrous. The comber is a complicated machine composed of grooved feed rolls and a
cylinder that is partially covered with needles to comb out short fibers.
20


DRAWING:
In order to spin an even and regular yarn the silver should be uniform and
regular. The fibers should also be made parallel and oriented along the axis of the silver for
better control of the fibers during drafting in succeeding process and also for obtaining better
strength of yarn in spinning. The evenness of silver and parallelization of fibers are achieved at
the draw frame where 6 to 8 or more silvers are blended together and drafted to get one silver.
The draft will be equal to the no of silvers blended.
Drawing is the first process in yarn manufacturing that employs roller drafting. In
drawing, practically all draft results from the action of rollers. Containers of sliver from the
carding process are staked in the creel of the drawing frame. Drafting occurs when a sliver is fed
into a system of paired rollers moving at different speeds.
Drawing straightens the fibres in the sliver by drafting to make more of the fibres
parallel to the axis of the sliver. Parallelization is necessary to obtain the properties desired when
the fibres are subsequently twisted into yarn. Drawing also produces a sliver that is more uniform
21

in weight per unit of length and helps to achieve greater blending capabilities. The fibres that are
produced by the final drawing process, called finisher drawing, are nearly straight and parallel to
the axis of the sliver. Weight per unit length of a finisher-drawing sliver is too high to permit
drafting into yarn on conventional ring-spinning systems.

SIMPLEX:
We have come from blow room to carding to draw frames and now we enter the
frames department also called as roving department or simplex department.
Simplex department are used to increase the yarn quality and strength. The hank
cotton is converted in to bobbin at this department. The bobbins colors are red, yellow, and ash
color. The hank with bobbin weights is 1kg to 1.5kg each.
SPINNING:
In this spinning department the rover yarn will be more thinned at this section.
Before the simplex department we called the cotton name as hank, but at the stage of entering
the hank into the spinning department it is called as yarn. The spinning department is having
15000 spindles, which helps to making yarn production. The spinning department converts the
big bobbin hank into small bobbin; the weight of small bobbin weight to 50 to 55grams only.
The spinning department is converting the 1000 meter hank onto 26000 meter yarn.
Spinning is the single most costly step in converting cotton fibres to yarn.
Currently, over 85% of the worlds yarn is produced on ring-spinning frames, which are
designed to draft the roving into the desired yarn size, or count, and to impart the desired amount
of twist. The amount of twist is proportional to the strength of the yarn.
The ratio of the length to the length fed can vary on the order of 10 to 50. Bobbins
of roving are placed onto holders that allow the roving to feed freely into the drafting roller of
the ring-spinning frame. Following the drafting zone, the yarn passes through a traveller onto a
spinning bobbin. The spindle holding this bobbin rotates at high speed, causing the yarn to
balloon as twist is imparted. The lengths of yarn on the bobbins are too short for use in
22

subsequent processes and are doffed into spinning boxes and delivered to the next process,
which may be spooling or winding.

REELING:
Reeling department helps to create a reeling yarn using for handloom production.
That is silk sarees, cotton sarees handloom production. It is the raw material for handloom
products. In this department 12 machines are used for production purpose.
The following types of reeling are available, they are
a. Single hank plain reel (SHPR)
b. Double hank plain reel (DHPR)
c. Double hank cross reel (DHCR)


23

PACKING:
It is the final process. The finished yarn will be packed neatly and send to the
customer. The packing is base on the following type

A. Cone yarn weight
o 40 cone = 50kg
o 50 cone = 50kg
B. Reeling yarn weight
o 40 bundle = 200kg (1 = 5 kg)
o 20 bundle = 90kg (1 = 4.5 kg)
LEARNING:
I learned from this department how to twist the different kinds of yarns.
The production department carries out activities of spinning.
They have machineries to convert cotton into thread.










24

MARKETING DEPARTMENT
Marketing is perhaps the most important activity in a business because it has
a direct effect on profitability and sales. Marketing is basically your interaction with your
consumer. This interaction with your consumer is done so that you can get the consumer to
purchase your product or service. Basically that is what marketing is all about. Marketing should
be done for the right product, in the right place, at the right time, at the right price.
Distribution area:
Distribution area is all over tamilnadu in polymer industry.
Advertisement:
The advertisement of the company is news paper, business magazines etc..
Price strategy:
The price has to fix by all person. The product is sold to only whole seller.
Mode of transport:
The transport of goods is all over tamilnadu. The goods transport through rail and
road ways. The transport of the city is mini auto and Omni.


25

Delivery method:
The delivery of goods is not the free delivery. The amount charged depends upon
the distance travelled.
Competitors details:
The customers for the products are yarn producer, polymer industry etc.
LEARNING:
I learned from this department how to do the marketing activities and also how to
attract and analyze the consumer.
This department has direct contact with all their customers.
The needs of customers are enquired and are satisfied.
Discounts are given to customers in festival season.











26

FINANCE DEPARTMENT
Introduction
The accounting department typically handles everything that keeps the business
running. It depends on the company. For most though, it means keeping the books. That means
maintaining checking accounts, payroll, tax preparations, financial statement preparations,
analyzing the companys profitability, meeting with regulators and auditors, creating budgets,
etc..

Functions of Finance Department
The company maintains a clear and perfect accounting system. The main activity of
the finance department is working capital management. Preparation of fund flow statement, cash
flow statement, balance sheet, profit and loss accounts are also the activities of finance
department. Secretarial work relating to board comes under the finance department. Most the
activities carried out by the finance department are preparing to long term and short term
requirement of the operation, closing purchase bill, maintaining the account contractors,
subcontractors, income tax, deduction, salary discrepancy, dealing with the financial institutions
with import and exports.
27

Accounting system
The financial statements are prepared on historical cost and convention.
All fixed assets are states at cot adjusted by revaluation in case of certain land, building,
land and machinery and electrical installation, less accumulated depreciation.
Long term investments are stated at cost less provision
Values of fixed assets are devalued by technicians
Valuation of investment is done at cost.
Depreciation is done as per the companys act 1956.

Management of Payables and Receivables:
As 90% of the sales are as exports, it takes place with the support of letter of credit or
bank guarantee. Therefore, management of payables and receivables has not been a problem for
the company. In this total amount, 50% of the total amount is written off as bad depts. Likewise
80% of the raw cotton purchased is imported. So L/C is made us here too. Local purchase is
made by the company for a credit period of 30 to 90 days. The company claims to have an
efficient management of both payables as well as receivables.
Investments:
Long term investments are stated at cost less provision, if any, for other than temporary
diminution in the value of investments.
Inventories:
Inventories are valued at lower of cost or net reliable value. Cost of Raw Materials is
computed by using Specific identification method and for other inventories Weighted
Average method. The cost includes costs of purchase, cost of convention and other costs
incurred in bringing the inventories to their present location and condition.

28

Sales:
Sales are recognized as and when risks and rewards of ownership are passed on to the
buyer and ultimate realization of price is reasonable certain. Export sales are inclusive of deemed
exports while local sales are net of sales Tax/ VAT.
Borrowing Cost:
Borrowing Cost attributable to acquisition and construction of qualifying assets are
capitalized as a part of the cost of such asset up to the date when such asset is ready for its
intended use. Other borrowing costs are charged to profit and Loss Account.
LEARNING:
I learned from this department how to allocate the finance to different
departments and how to maintain the finance records.
The finance department is provided with computers.
Every person is used and entry to the computer.
They maintain separate account for journal, ledger, petty cash, balance sheet
etc.








29

HUMAN RESOURCE DEPARTMENT
Introduction
Personnel Department plays a crucial role in the management of the company.
The department try to create and utilize an able and motivated workforce to accomplish the
organizational goal, and try to satisfy individual and group needs by providing adequate and
equitable wages and incentives, employee, benefit and social security and measures for
challenging work prestige, recognition security, status etc.
The personal department is responsible for recruitment, selection, placemen
training performance, appraisal, promotion and separation. This department is headed by DGM
(industrial relations). He is in charge of implementation systematic recruitment procedures for
providing facility for the overall development and motivation of all the employees. He is also in
charge of ensuring safety aspect in the mill and maintaining cordials industrial relation with the
workers. The categories of workers employees in KUMAR are permanent and temporary. The
recruitment, employment, leave disciplinary actions, retirement etc. are done as per the standing
order. This department is also responsible for training, performance appraisal compensation and
separation.
Functions of personal department
Recruitment and selection
Induction training procedure
Training
Evaluation
Performance appraisal
Wage and salary Administration
Recruitment and selection
Kumar spinning Ltd recruits its manpower resources through recruitment agencies and
advertisement in leading newspapers. The other sources are form reference service and relatives
30

of employees and from apprentices. Recruitment is done b the G.M. of personnel and industrial
Relation Department. At Kumar spinning selection is done through tests and interview.

Induction Training Procedure
Technical and non technical fresh recruits are given general exposure to the overall
activities of the organization during initial days. There after they are given in depth training in
assigned areas of work followed by on the job training.
Workmen fresh recruits are given general exposure to the overall activities of the
organization. They are on the job training under the supervision of the jobber/ mastery, guided
by supervisors.
Training
Training is given to all workers for developing their skills and proficiency in work. The
probationary period for also workers and office staff is six months. A formal induction training
program is provided for fresh recruits as per the program given in the induction training manual.
Also training is given to each worker when a new machine is installed respective to their
department.
31

Evaluation
On completion of training an evaluation regarding effectiveness of training received is
sought from the department concerned.
Wage and Salary Administration
KUMAR follows time rate wage system. For this purpose the attendance records are
maintained strictly also there is card punching system for recording entry and exit of the
employees and workers. The remuneration for the work of service rented by the employees is
paid in the form of salaries, wages or fringe benefit. Wages include both monetary benefits and
non monetary benefits. There is no PF and ESI for over time and holiday work.
Employee welfare schemes
The company provides all the statutory welfare measure as per the factorys act 1948.
There are general measures and the company also administers activities that come under non-
statutory items.
Employee credit society
Kumar spinning employees credit society advanced loans to the employees ranging from
Rs. 2000/- to 25000/- for various purposes on a reduced rate of interest. They also run recurring
deposit schemes for the employees.
Holidays
Each employee can avail 13 paid holidays in a calculating year. List of holidays will be
notified each year.
Canteen
A subsidized canteen managed by the employee representatives is taken care of catering
needs of the employees. Meals, snacks, coffee/ tea are available in the canteen during the
prescribed timings.


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Safety
Safety, housekeeping activities are arrived out on a continuous basis. A part from the
statutory compliance; a safety committee is effectively working.


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Employee welfare fund
There is fund constituted for the welfare of the employees. There are different benefits
like death benefit, retirement benefit, disablement benefit, loans assistance, etc.

Assistance for the handicapped children
There is a scheme to assist the handicapped children of employees; this includes supply
of artificial limbs, aids or any other assistance to such cases.
Blood Donor Group
Blood Group of almost all employees has been ascertained. In case of emergency,
employees will come forward to donate blood.
Suggestion scheme
The company conducts suggestion scheme in the areas of productivity, housekeeping,
quality, safety, etc. employees who submit suggestions are being properly rewarded
Attendance award
To recognize the employees to attend word regularly special prices given every year.

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Subscription to News Paper and Journals
Various News papers and journals are being subscribed for the benefit of employees
Standing orders
There is an approved standing order, which regulates the conditions of employment
Excursion tours
Excursion tours are arranged regularly for the staff member and for the participation the
workers education classes
Health and safety
There is a safety committee for looking after the safety of the workers drinking water
facilities are priced different spots inside the company.
Employee state insurance scheme
ESI scheme is unique multidimensional self financing social security scheme in which
every contributor is a benefactor and beneficiary. This integrated scheme of health insurance
prides comprehensive medical cover and cash benefit in contingencies of sickness, maternity,
disablement and health.
LEARNING:
I learned from this department how to recruit the employee and how to evaluate
the performance of the employee.
Most of the people working here are aged more than 40 years.
Only people operating a computer system are young employees.
Employees here have enough experience.


35

QUALITY ASSURANCE DEPARTMENT
Introduction
Quality control is a process by which entities review the quality of all factors
involved in production. This department should be in every firm for preventing errors before the
product reaches the hands of the customer.

Functions:
This help to check the quality of each product.
It is also helps to find damaged product before delivering the product.
Every employee is expected to take responsibility for managing quality issues
in order to make sure that waste is minimized and quality maximized.
Quality Policy
Kumar spinnings would ensure manufacturing and marketing of cotton yarn by
complying with:
Kumar spinnings ltd. would achieve the highest level of customer satisfaction by meeting
their stated and perceived requirements manufacturing consistency and timely delivery.
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Kumar endeavors continual up gradation of product quality and technology supported by
R &D efforts in a cost effective manner.
Kumar would inculcate a sense of quality awareness at all levels by using appropriate
training and motivation techniques.
Kumar would aim at preserving the environmental conditions y adopting eco- friendly
measures in its manufacturing and other activities.
The man activities of QAD are:
Raw material selection and stock
Bale management
Online process monitoring of production and quality.
100% zero/ quantum clearer
UV lamp testing
AWARDS OF THE COMPANY
Best implementation award in 5s technique.
ISO 9001:2000 certified award in the year 1990.
Quality implementing has started in the year 1994.
TPM is implemented in the company.

LEARNING:
I learned from this department how to produce the finished goods based on
customer spefications.
How to increase the good quality maintain the department.
How to improve the quality and maintain the quality of goods.



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ENGINEERING DEPARTMENT:
Engineering Department is engaged in the following maintenance work.
Machine maintenance:
Machinery repairs & break down
Utilities maintenance:
Generator, boiler, chilling, plant & pumps mould machine, Mixture Machine
Drop door & Two Roots etc.,
Civil maintenance:
Civil maintenance means there proper furniture should be provided for the office. There
may be many breakage in the furniture new furniture should be replaced for that one. A garden
should be properly maintenance.
A factory should be clean from the dust and fumes. The window and wall should paint
once in a year. Where the working climate is very hot so air conditions, air coolers, fan should
be provided.
Environment maintenance:
The Environment maintenance means an chemical and water can be properly treating.
Dye water should be kept as clean once in a week. Reduce recycle, reuse and properly dispose
all the wastages.
LEARNING:
I learned from this department how to maintain the machine and power equipments.
How to maintain the machinery in production area.
How many times to service the machinery in the year.




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OFFICE MANAGEMENT:
Office is a administrative centre for a business. The main purpose of office is to
provide the service of communication and record keeping.
The factory maintains & office stationary is pen, pencil, carbon, stamp pad, paper
weight, written pad etc.
The office equipment is used to the computer, printer, telephone, calculator,
daybook to be maintaining the office.

OFFICE EQUIPMENT:
Computer:
A computer is used to the entire department is an important in company. The record
and day-to-day transaction and other details of the factory are computerized.
Printer:
An ink-jet printer is used in the factory to take important copy of records and bill
vouchers.
Telephone:
An intercom is provided to the department to have a communication with all the
persons.
Calculator:
The factory provides calculator to the finance, production and purchase department.
Day book:
a day book is maintained regularly to record all the petty expenses and daily report.
Filing:
Various files are maintained in the a-z method. The files were checked and verified once in
a week.

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CASE STUDY

Problems observed in spinning industries:
Power system apparatus over heating:
It is normally observed that transformer gets overheating extra fans near transformer and
at places water sprinkler are installed to cool the transformer. Long term distribution panel doors
are kept open and cooling fans and even air conditioning of panel room is carried out to cool the
switch gears, bus born in the room. Bursting of provident fund capacitors due to excessive
harmonics was reported. Over correction of provident fund leading to increase of long term
voltage has damaged the sensitive components of VFD used in machineries.
Detailed harmonic measurement study on presence of harmonics and their effects on
more than 20 textile industries have been carried out. Following table shows the percentage. The
content present at the PCC of various machineries. The heating of power transformer in the
presence of harmonics analyzed. The theoretical calculations of heat loss along with the
measurement were carried out. Fifteenth National Power System Conference (NPSC), current for
spinning mill machineries.
Conclusion:
The maximum savings due to cancellation on of harmonics from the power transformer
comes from the eddy current loss component of the total load loss of the transformer. This eddy
current loss increases with the increases in current THD came down to 15% at the secondary of
the transformer due to other feeders supporting linear loads powered by the same transformer.
The saving in energy can be up to1% of the rated load capacity in spinning mills where variable
frequency drive with 6- pulse rectifiers are used. The savings may further come down with the
advent of new technology for improving the eddy current losses for the transformer.





40

SWOT ANALYSIS
The SWOT analysis is an extremely useful tool for understanding and decision-making for
all sorts of situations in business and organizations. It is a strategic planning method used to
evaluate the Strengths, Weaknesses, Opportunities, and Threats involved in a project or in
a business venture.
STRENGTH:
1. Effective management.
2. Quality of production.
3. Products are well accepted in the market.
4. Satisfactory organizational set-up with experienced and well-qualified employees.
5. Experienced promoters in the industry
WEEKNESS:
1. Lack of transportation.
2. Lack of infrastructure.
OPPORTUNITY:
1. Increasing demand of yarn for local oriented production.
2. New customers.
THREATS:
1. Competition in domestic market
2. Changes in Government policy regarding taxation and related matter.
3. No government support for textile industry.



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FINDINGS

There is poor communication between employees and management.
There are no new machines in the company; this company is not able to purchase new
machines due to finance problems.
Frequent power cut affects the production.
The fire accident safety measures are not provided


SUGGESTIONS
To improve the good communication between employees and management.
To apply loan for financial institution to purchase new machinery and produce good
quality of product.
Regular supply of electric power should be made available without any fluctuation. So as to
facilitate the continuous flow of production in the factory.
The fire accident safety measure has to be provided in the factory in dangerous area and also to
provide emergency exit.













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CONCLUSION
The trainee came to know about the several concepts of business administration,
functions of a manager in various situations and relationship between the employer and
employees. The training period was very useful and beneficial to the trainee. The trainee has got
great experience and acquired knowledge in this inplant training. During the training period,
Accounts Department helped the trainee to gain more knowledge.
The training is a good opportunity for the trainee to gain practical work knowledge. The
unit maintains good co-ordination with various departments such as Purchase, Sales, Finance,
HR and Production. It is helpful in future to work in any organization and understand the
activities of department.
The proper training provided the trainee creates sense of confidence and coordination.