COIMBATORE
Submitted by
Arun Mathew
Reg No :098001185003
Lecturer
AUGUST - 2010
BONAFIDE CERTIFICATE
This is to certify that the Inplant training report submitted to Anna University of
Technology, Coimbatore in partial fulfilment of the requirements for the award of the degree
of MASTER OF BUSINESS ADMINISTRATION is a record of original research work
done by Arun Mathew during the period June 2010 to July 2010 of his study in RVS
FACULTY OF MANAGEMENT, Kannampalayam, under the supervision and guidance of
Ms.Uma Maheswari K and the training report has not formed the basis for the award of any
Degree/ Diploma/ Associateship/ Fellowship or other similar title to any candidate of any
university.
Date:
Place:
DECLARATION
I, Arun Mathew hereby declare that the Inplant training report submitted to Anna
university of Technology, Coimbatore in partial fulfilment of the requirements for the award
of the degree of MASTER OF BUSINESS ADMINISTRATION is a record of original and
independent research work done by me during June 2010 to July 2010 under the supervision
and guidance of Ms. Uma Maheswari K, B.com, MBA Lecturer, RVS Faculty of
Management, Kannampalayam and it has not formed the basis for the award of any Degree/
Diploma/ Associateship/ Fellowship or other similar title to any candidate of any university.
I am deeply indebted to my faculty guide Ms. Uma Maheswari K, B.com, MBA for
his/her scholarly guidance, valuable suggestions and encouragement throughout the duration
of this project.
I also express my gratitude to the respondents, Parents, and dear friends without
whom the project would not have been successful. Above all, I wish to thank the almighty for
giving courage and wisdom to take up this project and complete it successfully.
ARUN MATHEW
CONTENTS
1 1. INTRODUCTION 1-2
1.1. ABOUT INTERNSHIP TRAINING
5 CONCLUSION 65
6 BIBLIOGRAPHY 66
7 APPENDIX 67-69
I. INTRODUCTION
Internship training is an exercise for the students who are undergoing M.B.A
program. The objective of the study is to make the student familiar to the current industrial
scenario. It provides the student with the first hand idea on the general working of the
organization. The students get an environment where he/she can actualize the knowledge he
has acquired in his curriculum. The exercise is an opportunity for the student to understand
the organizational structure, the major departments, flow of information and various other
functions in an organization.
Some of the things that can be learned from this training are
To acquire the knowledge about the organization setup of Thiruvannur cotton Mills
Pvt Ltd.
To analyze the effectiveness of Malabar Spinning & Weaving Mills and give the
recommendation to improve existing sales and production.
To analyze the consumer behaviours and to study the parameters influencing the
purchase decision.
To study and analyze the production performance of Malabar Spinning & Weaving
Mills
SCOPE OF STUDY
The present study is based up on the activities of Malabar Spinning & Weaving Mills,
P.O. Thiruvannur Nada, Calicut-673029.
METHODOLOGY
The study is based on both primary and secondary data. The primary data are
collected from the manager and other members of company and secondary data are collected
from annual financial statements.
The complete details are not available from the firm and therefore scientific method
could not be employed.
The information is collected from the different departments from the firm.
The time allowed for the study is only a few weeks. It is not sufficient to make an
intensive study of the unit.
INDUSTRY PROFILE
II. INDUSTRY PROFILE
The country’s cotton production has been steadily on the rise with better farm
practices. The average yield has increased to 500 kg per hectare. From a level of importers of
cotton, India has become an exporter of cotton earning a name in the international market.
Presently India is second largest cotton producer in the world next to US and about to
overtake the US as the number ONE in the next couple of years. It is the result of various
factors. Primarily because of rising cultivations of Bt.cotton (Bacillus thuringnsis) and reduce
the farmers input costs, while the yield as well as quality are substantially much larger
compared to traditional varieties. In view of this development, the cotton cultivation acreage
has been steadily going up in India. The farmers have become more knowledgeable to follow
scientific methods to cultivate high yielding long staple cotton varieties.
Besides individual mills are also simultaneously taking steps to improve the cotton
production along with Technology Mission on cotton (TCM), the cotton development
research Associations of organizations (CITI), South Indian Textiles Mills Association
(SIMA) and Kerala State Textile Corporation (KSTC). The resultant factor is quality and
quantity of raw material supply has substantially improved in the country. Due to
globalization of our economy, the conscious of quality inputs and pricing have become
competitive to the international standards and prices. Supply of quality raw material
availability sources of raw material from major cotton exporting countries.
In brief, good business is generally the result of good organization which can
emerge only if it consists of good people who work together as a team. The textile industry
occupies a unique place in our country. One of the earliest to come into existence in India,
it accounts for 14 per cent of the total industrial production, contributes to nearly 30 per
cent of the total exports and is the second largest employment generator after agriculture.
The Indian textile industry is one of the largest in the world with a massive raw material
and textile-manufacturing base. Indian economy is largely dependent on the textile
manufacturing and trade in addition to other major industries about 27 per cent of the
exchange earning are on account of export of textiles and clothing alone.
In India organized textile mill sector has increased from 1787 in 2003-04 to 1789 in
2004-05. During the year 2003-04 the production of yarn was 3051.07 million kg and it had
increased to 3220.59 million kg in 2004-05. The number of workers worked in textiles mills
during the year 2003-04 was 9,28,000 and it have decreased during the year 2004-05 was
9,18,000.
India has the second-largest yarn-spinning capacity in the world (after China),
accounting for roughly 20 percent of the world’s spindle capacity. India’s spinning
segment is fairly modernized; approximately 35 to 40 percent of India’s spindles are less
than 10 years old.
During 1989-98, India was the leading buyer of spinning machinery, accounting
for 28 per cent of world shipments. India’s production of spun yarn is accounted for
almost entirely by the ―organized mill sector,‖ which includes 285 large. Man-made
fibers, wool and silk segment grew by modest 4.5 per cent per annum during the 5-year
period 2000-01 to 2005-06.During the first year of quota-free global trade, production
increased leaps and bounds. Textiles production increased 10 per cent over 2004. The
growth was fuelled by a 22 per cent rise in production of other textiles (including
apparels). Cotton textile also posted an increase of nine percent.
In the last six years, an estimated US$ 6.7 billion has been invested in the textiles
sector, aided by the Technology Up gradation Fund (TUF) scheme. The TUF scheme
expires in March next year (2007) and the quotas on China will be lifted in 2008. Hence,
companies will continue to add capacities over the next year. Also, according to CRISIL,
the sector is likely to rise over US$ 3.5 billion from the capital markets in the next few
years.
The cotton textile industry, one of the oldest and major consumer industries in India,
has assumed national importance by virtue of size, investment, output and employment. The
industry produces a wide range of fabrics to suit specific needs of consumers. Further, the
cotton textile industry occupies a pre eminent place in the Indian economy by contributing a
major share and to the countries industrial production and providing cloth to its millions. The
industry also serves by providing direct employment to 60,00,000 workers in several of its
related activities.
India is one of the largest textile producing countries in the world. The share of the industry
in the export basket of India is around 20%. However, textile industry is vast developing
sector and when the competitions are exorbitant especially in its design and quality we have
to adopt modern technology management, machine so as to complete with other countries in
the international market.
COMPANY PROFILE
III. COMPANY PROFILE
Malabar spinning and weaving mills is one of the premier textile industrial
establishments in Kerala. Ever since its inception, this mill has played a dominant role in the
industrialization of the whole Malabar. It is the first textile mills in Kerala and cotton textile
is the first industry in the whole Malabar. This mill was honored with a ― Certificate of merit‖
form the Government of India for its outstanding performance in exporting in 1975.
The mill, popularly known as ―Thiruvannur cotton mill‖ is located in an area of 14.7t5
acres at Thiruvannur which is 6 kilometers south-east to Kozhikode town. It was in the year
1884, the foundation stone for this mill was laid down by W.H.Will Kingston, the district and
sessions Judge of Malabar. The site for the factory was initially brought from the famous
―Kozhippuram Tharavadu‖ on lease for 99 years.
In its initial stage the company had made an opportunity to give employment to 200
labourers. By using its own fund the company started a general hospital under the name
―Prince of war‖. The same hospital is still functioning at Panniyankara in Kozhikode under
the jurisdictions of corporation of Calicut. The management had to close the company several
times due to financial stringencies. The subsequent closure due to financial losses in the years
1966, 1969 and 1976 compelled the Kerala Government to authorize the power of the
company to Kerala State Textile Corporation [KSTC] under the relief undertaking Act in
1978 for 5 years.
It was in the year 1983 the Kerala Government decided to take over the mill
completely and the name has been changed to Malabar Spinning & Weaving Mill in 1989,
the management stopped the weaving section of the mill due to financial losses. Fifty percent
of the weaving workers voluntarily retired and the remaining were transferred to spinning
section.
THE COMPANY AT A GLANCE
CHAIRMAN
M.D
Ganesh [KSTC]
GENERAL MANAGER
George
FINANCE MARKETING
Rajitha Vijayalakshmi
Susmitha
Ramachandran
Anoop
PRODUCT:
COTTON YARN
PRODUCTION RESOURCES
2. Electrical power
3. Labor
4. Stores
5. Packing material
Presently Cotton is used as raw material which is bought from local and other
states. Depending upon the yarn demand situations, the management will take orders for the
raw cotton and likewise the production takes. The major contribution of cottons where from
Andra Pradesh, Tamil Nadu, and Karnataka etc
DEPARTMENT PROFILE
IV. DEPARTMENT PROFILE
Marketing department
Production department
Finance department
Systems department
HUMAN RESOURCE DEPARTMENT
IV.1. HUMAN RESOURCE DEPARTMENT
GENERAL MANAGER
George
PERSONAL OFFICER[H R]
Sreejith
TIME KEEPER
Vijayakumar
Manpower Planning
Recruitment
Training and Development
Induction
Wages and salary administration’
Statutory compliances
Leave administration
Grievance Redresser
Personal counselling
Compensations and Benefits
Welfare
Performance evaluation
-Sources of recruitment
Recruitment is the process of filling the vacancies. It is the first steps in selection
process.
In Cotton Mill direct recruitment method is used frequently for recruitment .The firm
places job advertisement in Malayalam and English newspapers. And in TV, media and tries
to attract as much as calibre people from the outside.
The company also have internal recruitment for filling the post by efficient and
skilled workers from the rank , promotion and Corporation have preferred local candidates
who belongs to surroundings.
There will be notice displayed on the notice board of the company and outside of the
company and like that workers will be recruited. As it is a Govt company staffs and managers
will be recruited according to P.S.E exams.
-Methods of selection
The basic requirement for a employees is 10th pass and other office staffs and all will
be according to the Govt norms. The General Manager will conduct the interview, and from
that he will appoint the employee. While selection they will try to avoid very sick person and
old persons
There will be regular training & development programmes for all levels of employees,
i.e. Senior Management to lowest level workers regularly.
How the training need is analysed for present employee, based on their performance
or while technology advances. To improve the quality of production or to reduce the cost
factor or avoiding accidents. Training need analysis is mainly done when a new worker joins
the company or when a new machine is placed then for the machinery handling and
maintenance. Training Analysis (sometimes called Training Needs Analysis (TNA)) is the
formal process of identifying the training gap and its related training need.
1 INTRODUCTION
2 DESIGN INTEGRATED TRAINING ANALYSIS
INTRODUCTION
Training can be described as ―the acquisition of skills, concepts or attitudes that result
in improved performance within the job environment‖. Training analysis looks at each aspect
of an operational domain so that the initial skills, concepts and attitudes of the human
elements of a system can be effectively identified and appropriate training can be specified.
Training Analysis is most often used as part of the system development process. Due to the
close tie between the design of the system and the training required, in most cases it runs
alongside the development to capture the training requirements.
K Tara Smith proposed and developed tools and methods for an integrated approach
Design Integrated Training Analysis, where the trade-offs between design and training are
both assessed in the light of the understanding of the operational tasks. This is being followed
in Malabar Cotton Mills
This approach also used information regarding recorded critical incidents to review proposed
training and to provide traceability between hazards and training.
TRAINING ANALYSIS PROCESS
Over the last 20 years the critical nature of the man-in-the-loop has changed from simply
manual dexterity and procedural operation to a state in which their decision making,
cognitive abilities, data assimilation, communication skills, and attitude are all crucial. In
addition the job structure of the personnel operationally involved with modern systems has
diversified in direct proportion to the complexity of the technology. This has fuelled the need
for a formal approach.
The task of training can be broken down into a number of discrete components, each
addressing a different part of the overall learning process. This breakdown is as follows:-
Psycho-motor Skills
Procedural Skills
Knowledge Transfer
Communication Skills
Colossal Thinking
Attitude Learning
Performance training.
The role of training analysis is to build a formal bridge between the available design data and
the training media and training objectives, in order to facilitate the transfer of training
elements into the operational environment.
For complex multi-user system a user-to-task map is often constructed to present the
relationship between the tasks and the identified team structure and also to identify new
groups of users that would need to have an understanding of the system. The training gap is
assessed by a comparison between the goals and tasks undertaken by the individuals and the
existing training.
There is a wide variety of training media that can be used, ranging from traditional lecture-
based teaching to sophisticated simulators. Different media will be more or less appropriate
for different activities. It is necessary to determine the most suitable and cost-effective
training media for the different areas.
There have been many different approaches defined however the system approach to training
has been the most successful.
Training Needs Analysis (TNA) is defined as the ―Identification of training requirements and
the most cost effective means of meeting those requirements‖.
Carrying out all TNA activates in accordance with SAT principles ensures rigorous visibility
in each design stage with clear audit trails from the initial Scoping Study through to the
recommended solution.
The needs analysis is usually the first step taken to cause a change. This is mainly because a
needs analysis specifically defines the gap between the current and the desired individual and
organizational performances.
1. Performance problems
In all three situations, the starting point is a desire to effect a change. Given this, you
must know how the people who will experience change perceive it. In the absence of a needs
analysis, you may find employees resistant to change and reluctant to training. They may be
unable to transfer their newly acquired skills to their jobs because of the organizational
constraints.
A needs analysis often reveals the need for well-targeted training areas. However, we
must keep in mind that training is not always the best way to try to close a particular gap
between an organization’s goals and its actual performance. Those conducting the needs
analysis must get a clear idea of the problem, look at all possible remedies and report on their
findings to management before deciding on the best solution.
When properly done, a needs analysis is a wise investment for the organization. It
saves time, money and effort by working on the right problems. Organizations that fail to
support needs analysis make costly mistakes; they use training when another method would
have been more effective; they use too much or too little training, or they use training but fail
to follow up on it. A well-performed analysis provides the information that can lead to
solutions that focus on the areas of greatest need.
In many ways, the needs analysis is like detective work; you follow up on every lead,
check every piece of information and examine every alternative before drawing any solid
conclusions. Only then you can e sure of having the evidence on which to base a sound
strategy for problem solving.
Training needs will differ with the backgrounds of the employees to be trained, and their
present status in the organization. Basically, a candidate for training may come from any one
of three groups :
1. NEW HIRES
2. VETERAN EMPLOYEES
Consideration of the varying needs of these groups provides a frame of reference for
discussing and suggesting the methods of identifying training needs :
• NEW HIRES
Addition of new employees creates high and low peaks in placing new persons into the
training program. This problem may be solved by a program where progression is made in
different sequences. It will eliminate a jam that will occur if all phases of the program must
be taken in a definite sequence.
The new employees will normally be of somewhat different backgrounds. Being new, they
are not familiar with their new employers. As a result, the earliest phases of the training must
concentrate on company orientation. During these phases, the organi- zation, organization
policies and administrative details should be covered. It is also a suitable time to acquaint the
trainees with what will be expected of him, and how he will be evaluated throughout the
phase of training.
The people in this category offer a real challenge to the training department. There- fore, the
number and amount of training required by this category should be carefully considered.
Often the retraining and upgrading of former employees can be very rewarding for training
instructors. At least two schools of thought exist as to how these employees should be
rekindled. There are advantages in keeping this group intact and tailoring the program to their
needs. On the other hand, this category of employees can also make significant contribution
to training if they are co-mingled with the new hires.
A good training program will normally have participants in various phases of completion. An
awareness of completion dates and how the potential employee will be employed should be
the concern of the training staff and also the employee’s supervisor. A trainee should have a
challenge in all phases of his training. All these challenges should not be confined to those
phases where the pipeline employee is sitting in a classroom. Therefore, it is recommended
that thorough interim test-work be given to pipeline employees in periods between formal
classes. This may take the form of solidifying what he learned in the prior phase and serve as
preparation for the coming phases.
There will be both on the job & off the job training. Off the job training is imparted
based on the need and category of staff. Generally training is given to a group and there will
be external training institutes called upon for giving training for the employees.
The trainee receives an overview of the job, its purpose and its desired outcomes with
a clear focus on the relevance of training.
The trainer demonstrates the job in order to give the employee model to copy.
The employee is permitted to copy the trainer’s way.
Finally the employee does the job independently without supervision.
Coaching
Mentoring
Job rotation
This kind of training involves the movement of trainee from one job to another. This
helps him to have a general understanding of how the organization functions. The purpose of
job rotation is to provide trainees with a larger organizational perspective and a greater
understanding of different functional areas as well as a better sense of their own carrier
objectives and intervals. Apart from relieving boredom, job rotation allows trainees to build
rapport with a range of individuals within the organization, facilitating future co-operation
among departments.
OFF THE JOB METHODS
Vestibule training
In this method the employees are trained in a separate part of the organization. Actual
work conditions are stimulated in a class room.
Materials those are used in a job performance are also used in the training.
Role playing
Lecture method
Conference or discussion
This method involves a group of people who pose ideas, examine and share facts,
ideas and date, test assumptions, and draw conclusion, all of which contribute to the
improvement of job performance. The discussion involves two way communication
and hence feedback is provided.
Programmed instruction
The assessment of the training is mainly done by monitoring the work of the
employee, if that person is well working then the training was effective if the person is not
working properly then the training was not effective. Every month there will be an orientation
class for the development of the employees.
Induction & orientation is given to the newly joined employees. A group induction is
organised for the newly joined group of employees once in 6 or 12 months. There will be
orientation classes given to the whole employees once in six month.
The performance appraisal system in the company is that when a person joins the
company at first he will be a trainee and after completion of two years then he will be a
permanent employee. So for the trainee, they will be earning a low wage and when he
becomes permanent the wage also increases. By each year the salary or the wage also
increases according to the number of years he worked in the firm.
-Motivation methods
There are motivation classes and all conducted by various persons and aattendance award is
given to all employees who are present in the mill for a certain number of days.
Salary hike
Bonuses
Incentives
Allowances
Other Facilities
-Labour welfare facilities
There are several welfare facilities some are canteen, rest room recreation room,
library etc.
The first aid boxes of cupboard shall be distinctively marked with a red cross
on white background. First aid boxes shall contain sterilized dressing, sterilized burn
dressings, one bottle of mercurochrome solution in water, and one bottle of adhesive plaster,
sterilized eye pads, tablets of aspirin or any other analgesic. Polythene wash bottle containing
potassium permanganate crystals. These first aid facilities are provided here in all
departments.
CANTEEN
The company has a canteen which is one of the most efficient parts of the
company. The canteen is working in all the shifts. The facilities are available to all the
employees. Each employee is given tokens monthly. The management charges only a
nominal amount for the fund. the amount is deducted from the salary of the employees.
HOSTEL
The company provides the facility for workers to stay within the campus of
the company by having a hostel with it. With this facility, workers gain the place for shelter
with free of cost. as per management side, they can acquire labour at exact time for working.
TOILETS
The toilets are built separately for each department with good water facility.
For workers it is built separately in two areas for the convenience of the worker.
To safeguard the workers from the dust, company is providing aprons, masks
and caps for each worker, working in the company.
PENSION SCHEME
The scheme has been formulated for those employees who have retired from their job.
Pay role is according to the hierarchy of the organization. For the Managers and for
the staff as per the Government norms the salary will be there, for the permanent workers the
daily wages will be about 175 and for the trainees 125 excluding the other beneficial
payments and allowances.
There is a tendency amongst employees to test limits and act creatively in workplace
situations, so business houses also need a strategy for developing, communicating and
implementing HR policies that reflect their standards of acceptable behavior.
-Vision & mission statement
Usually when there is a need of HR then from other Govt organizations labors will be
called out on contract basis. Suppose where is an urgent then the labors will be hired from
sister companies.
Generally, grievances means any factors involving wages, hours of work or condition
of work environment. By grievances we can see that mostly between the trade unions and the
Government. So the trade union leaders will be out for open discussion and by that meeting
both will negotiate each other and last the grievance will be solved.
- Arbitration Process
Arbitration Process was done by each department heads and it will reported to the top
management at the Thiruvananthapuram if the matter is severe, and to Government and
KSTC.
-Product profile
-Department chart
GENERAL MANAGER
George
JUNIOR MANAGER
Preamen
OFFICE STAFF
Vijayalakshmi
KSTC
The main function of the company is that to provide the best standard yarn to the
companies who needs, and so by that a better quality cloth can be produced. If better quality
yarn is produced then soon there will be a high demand and likewise there will be external
demand increased. And so the export also takes place. By this a huge revenue also will be got
for the Government. The other main aim of the marketing department is that if there is an
order then soon without any delay the product should be reached at hands of the customers.
K.S.T.C will be mainly taking care of the product, they will be calling for tender and
who quotes the best price to them the yarn will be sold. If there is no sales then the yarns will
be taken to the godowns which are situated at Bombay and form their it will be sold.
Marketing strategy
According to the customer need and requirement the production takes place. And the
quality of the yarn also will be highly maintained. Mainly the change of the demand will be
like the yarn’s count so according to the change of the demand for the yarn, the market
demanded yarn will be produced.
The target is fixed only after the confirmation of the value of goods in market and if
the demand for the goods in the market is high or if any order is placed then according to the
order, the production process takes place.
Marketing product lines
The product lines of the cotton mill was marketed using the same channels and by the
same strategy. As per the orders and all reseved soon they will be producing the cotton yarn
as fast as they can and their by supplying to them.
According to the customer need and requirement the production takes place. And the
quality of the yarn also will be highly maintained. Mainly the change of the demand will be
like the yarn’s count so according to the change of the demand for the yarn’s count, the
market demanded yarn will be produced
Each customer will be looking for their own standards of cotton yarn so each of them
need a totally different product. So according to the customer requirement and satisfaction
they have to produce the cotton yarn and that should meet the customer expectation.
As there will be orders from various customers then soon without making any delay
they will be producing the yarn and soon it will be delivered to them. As part from the
company they will be very keen about the standards of the yarn and all, as per the order they
will be producing high quality yarns and that will be delivered to them.
The company will be getting different quotations and all from various companies and
all from that they will be choosing the best that will be beneficial to the company. On the
other side a major part of the orders and all will be taken by KSTC and they will be allotting
to which customer they have to give the yarns. When the orders are received soon the
production for the order starts up and soon it will be delivered to them.
Marketing tools & techniques
A marketing strategy is an overall marketing plan designed to meet the needs and
requirements of customers. The plan should be based on clear objectives. A number of
techniques will then be employed to make sure that the marketing plan is effectively
delivered. Marketing techniques are the tools used by the marketing department. The
marketing department will set out to identify the include public relations, trade and consumer
promotions, point-of-sale materials, editorial, publicity and sales literature.
Market research enables the organization to identify the most appropriate marketing mix. The
mix should consist of:
As cloth is one of the basic necessity for man so for producing cloth there is the need
for the yarn so every year the demand for the yarn is increasing.
Demand analysis
While the production is going on KSTC will be looking for the sales by giving add on
newspapers and all and likewise there will be some quotations and from all that they will be
looking for which product they gets more orders and by analyzing those things KSTC will be
saying that what type of yarn to be produced.
Methods of overcoming competitors
The best method of overcoming the competitors are by supplying the best verity of
yarn with high quality. And selling that yarn by market rate price. By this the customers will
be always be there.
Market segmentation
Domestic
State
National
International
As the population is increasing day by day, the need for the cloth also increases as it is
one of the basic essentials for man. And so for producing the cloth the yarn is required. There
have been a steady increase of the demand for the yarn. As part of sales there have not been
any high advertisement but providing the high quality yarn is one of the promotion that the
company is getting. Apart from all these there have been quotations for sales and all which
will be published in websites.
Product publicity
There is no big publicity for the product but product sales tender notice will be
advertised in internet and in newspapers as well.
There will be quotations and all which will be got from various companies and
thereby the company will be choosing the best quotation and there by the yarn will be
delivered to them. Apart from all these KSTC will be playing the major role as they will be
taking initiative for selling the yarns.
PRODUCTION DEPARTMENT
IV.3 PRODUCTION DEPARTMENT
-Department chart
GENERAL MANAGER
George
Pradeep Preman
Sabu
Ramachandran Anoop
Layout design
Production process
Bales are different variety of cotton are opened and layer of cotton from able each are
fed alternatively with a view to obtain uniform blend. For getting different counts as yarn,
cotton of different variety and soft waste are mixed in a predetermined proportion. The cotton
for each mixing is fed into the plant in the blow room where external impurities are removed.
The compressed cotton opened into small tufts and a lightly compressed continuous sheet
known as LAPS are rolled upon cylindrical rod. The waste obtained in the process are
droppings, quality fly and lap bits. In the case of chute feed blow room the cotton converted
into sliver bye-passing carding.
CARDING
In this department, the cotton is completely opened into individual filters. Cleared by
removal of NEPS and foreign matters and silver is produced which is collected in cans. The
waste in the process is sliver waste cylinder fly, flat strips, roller strips and sweepings.
COMBING
In combing process cotton fibers are separated by needles and predetermined part of
sharp fibers is removed as waste and sliver is formed with suitable drafting. The fibers are
arranged in parallel format combing is an optional process of manufacturing better quality
and finer counts as yarn. This precedes the drawing and sliver laps process feeding.
DRAWING
In the drawing frame, sliver is produced by combing a specified number of sliver and
stretching them proportionately, the waste arising in the process is sliver waste and sweeping.
SIMPLEX
In this process, the thickness of drawing sliver is reduced and sliver is give twist and
wound on the bobbing. The production depends upon the spindle speed and twist per inch,
number of spindles etc. the waste collected in the process is roving ends and sweepings.
RING FRAME
The final yarn is spun on ring frame by drafting and twisting the rove from simplex.
The draft end twists vary depending upon the count, quality of yarn required. The yarn is
collected by winding on cops.
CONE WINDING
The yarn from ring frame is wound in cones suitable for market. In this process faults
like thin and thick places are removed by passing through slit cleaner. The auto corner has
facility of electronically cleaning the yarn and splicing instead of knotting in the conventional
cone winder. Saleable hard waste is obtained in this process.
DOUBLE WINDING
DOUBLING
The yarn received from double winding is twisted on ring doubling machine and
wound on cops. This yarn is taken to cone winding department for winding on cones for
market.
PACKING
The yarn is packed in the poly woven bags for the market.
-Loading
The cotton yarn cones will be loaded to very carefully without getting wet and all.
The raw cottons will be coming in bail forms weighing from 180Kgs to 200Kgs. The
raw cotton will be coming from Gujarat, Andhra Pradesh etc. The raw cotton will be carried
out carefully out to the godowns and from their each bail will be taken for cotton mixing and
for the production of yarn.
Scheduling
7:30AM – 3:30PM
3:30PM – 11.30PM
11:30PM – 07:30AM
Shifts constitutes of 8 hours including 1 hour break. So the industry works around
the clock day and night.
Inventory management
The main inventories in the company were raw cotton or cotton bales, spares and loose tools.
There is a chance of damages when the cotton rolls when stored for a long period so they are
carefully stored without getting wet and all.
As per their strategy they had a steady demand for materials so they stored the materials.
They have introduced new machines and all so the work goes more faster than earlier so
according to that they have ordered and stocked more cotton for the production. They will
collect and store cotton for an advance of one month’s production.
Research & development
R&D Department looks after a specific unit and develops new idea to attain
advantage in the area of that unit. R&D department is under the control of top management
itself. Technical development wing of R&D studies about the new technologies and update
the current technology with most sophisticated technology with take into consideration of the
requirements. At present new and most modern machines are replaced for the old ones.
Mainly the modern machines are from Germany and Lakshmi Mills Coimbatore. Product
development wing of R&D studies about the market and what are all the ways to improve the
products. The will be thoroughly looking for the demand of the yarn under what quality at
present they are producing 60count quality yarn so as per the customers requirement the
count of the yarn will be changed in order to meet the demand.
Supply in time
Cost effectiveness
Adapting changes as required to compete in the customer driven market.
Mentoring employees at all levels in reviewing quality and productivity
related objectives for continual improvement and sustainable growth.
Quality circles
For the quality circle there is a team where they will be monitoring the quality of the
yarn.
They will be constantly monitoring and if there is any sort of fault for the quality then
immediate action will be taken quickly.
Auditing & Inspection
There are mainly two types of auditing they are internal auditing and statutory
auditing. The internal auditor audits the accounts, resources and human resource etc. They
will be auditing everything on daily basis. Statutory auditing takes quarterly. There will be
through inspection of the machines and all if there is any problem then suddenly the adequate
measure will be taken and so by that the production continues without any halt. There are
inspections from head office also and it will be a sudden also it will be from K.S.T.C
Avoidance of accidents
Workers in the production department has prone to moving machines has a great risk
of accidents. The workers had given training to handle the machines with safety and to reduce
the accidents. The workers have to wear aprons and masks and shoes as well so by this they
avoid accidents. Accident is the son of carelessness, so care should be taken from the
workers level to avoid the accidents.
Safety measure
The administration very much takes care about the safety of the workers. Fire and safety
measures
Machinery safety
Machinery guards
The mill provides necessary numbers fire-buckets, fire-extinguishers are all placed in
each processing areas. There is an automatic switching system for machines to protect the
workers from the electronic shock hazard. This will automatically switched to off state when
will any short circuit occurs. As a safety for the employees aprons and masks are also given
to them. Apart from all these sufficient notices for safety are displayed in convenient places
in the factory.
Machinery maintenance
Every half an hour interval the workers will be inspecting the machines and they will
be cleaning the waste material which are stuck on to the machines and all. As part of
preventive maintenance they will be putting oil and grease for the machines. There will be
also inspection of the wear and tear parts of the machines as well.
Quality policies
According to the market demand the yarns quality also will be changed at present the
yarn should have 60 count and C.S.P 2400 above. So according to the clients order the
quality of the yarn also will be changed The main quality policies are supply in time, cost
effectiveness, adapting changes as required to compete in the customer driven market,
mentoring employees at all levels in reviewing and productivity related objectives for
continual improvement and sustainable growth.
10.Humidifier.
Product standards
According to the customers requirement the standard of the yarn also will be
maintained. There will be inspection of every yarn that they produce for checking of the
required standard. If the yarn doesn’t have the specified minimum standard then, the machine
will be tuned to the specific standard and thus the yarn will be producing according to the
standards.
Benchmarking
1. Identify your problem areas - Because benchmarking can be applied to any business
process or function, a range of research techniques may be required. They include:
informal conversations with customers, employees, or suppliers; exploratory research
techniques such as focus groups; or in-depth marketing research, quantitative
research, surveys, questionnaires, re-engineering analysis, process mapping, quality
control variance reports, or financial ratio analysis. Before embarking on comparison
with other organizations it is essential that you know your own organization's
function, processes; base lining performance provides a point against which
improvement effort can be measured.
2. Identify other industries that have similar processes - For instance if one were
interested in improving hand offs in addiction treatment he/she would try to identify
other fields that also have hand off challenges. These could include air traffic control,
cell phone switching between towers, transfer of patients from surgery to recovery
rooms.
3. Identify organizations that are leaders in these areas - Look for the very best in any
industry and in any country. Consult customers, suppliers, financial analysts, trade
associations, and magazines to determine which companies are worthy of study.
4. Survey companies for measures and practices - Companies target specific business
processes using detailed surveys of measures and practices used to identify business
process alternatives and leading companies. Surveys are typically masked to protect
confidential data by neutral associations and consultants.
5. Visit the "best practice" companies to identify leading edge practices - Companies
typically agree to mutually exchange information beneficial to all parties in a
benchmarking group and share the results within the group.
6. Implement new and improved business practices - Take the leading edge practices and
develop implementation plans which include identification of specific opportunities,
funding the project and selling the ideas to the organization for the purpose of gaining
demonstrated value from the process.
Cost of benchmarking
Visit Costs - This includes hotel rooms, travel costs, meals, a token gift, and lost labor
time.
Time Costs - Members of the benchmarking team will be investing time in
researching problems, finding exceptional companies to study, visits, and
implementation. This will take them away from their regular tasks for part of each day
so additional staff might be required.
Benchmarking Database Costs - Organizations that institutionalize benchmarking into
their daily procedures find it is useful to create and maintain a database of best
practices and the companies associated with each best practice now.
The cost of benchmarking can substantially be reduced through utilizing the many internet
resources that have sprung up over the last few years. These aim to capture benchmarks and
best practices from organizations, business sectors and countries to make the benchmarking
process much quicker and cheaper.
-Japanese Technologies
5s, abbreviated from the Japanese are simple but effective methods to organize
the workplace.
The 5s are,
Implementing 5s methods in the plant would help the company to reduce waste
hidden in the plant, improve the levels of quality and safety, reduce the lead time and cost,
and thus, increase company’s profit.
PQCDS:
P – Increase productivity.
According to the change in the market for the yarns count and its properties, the mill
will produce the yarn. When the customer comes and asks for a particular count of yarn
according to the customers need the yarn will be produced.
FINANCE DEPARTMENT
IV.4.FINANCE DEPARTMENT
The word finance comes from the Latin word ―fins‖. Finance is the art and science of
handling money. It is the management of money. It is the management of laws of money. It is
the management of laws of money through as organization.
First approach
In the words of F.W.Paish ―Finance may be defined as the provision of money at the
time it is wanted. This approach is concerned with procurement or raising of funds and hence
this is a narrow approach‖.
Second approach
According to J.J.Hampton, ―the term finance can be defined as the management of the
flows of money through an organization, whether it will be a corporation, school, bank or
govt. agency. This a road approach.
Third approach
This is the modern approach and is the most acceptable one. According to this
approach, finance function is concerned with the procurement of funds and there effective
utilization it the business. According to the Solomon Ezra, the finance function covers not
only the raising of funds but also their effective utilization in the business. This approach is
related in the business. This approach is related in the business. This approach is related with
the financial decision making ie. The financial manager should consider the alternative uses
and sources f funds. In short, finance function is defined as provision of money at the time
when it needed.
To check all the vouchers, bills, receipts.
To draw money from the bank for any cash transactions.
To pay the amount due to the supplier outstanding and creditors.
To pay the amount to the tender purchases.
To check all the register relating to accounts section.
To prepare and furnish all furnish all return and remitting the sales tax and central
excise and other local taxes and rates.
Sending of periodical returns and remitting the sales tax and central excise and other
local taxes and rates.
The accounts department should pay salaries, wages and other monetary benefits to
the workers and staffs.
-Department Chart
GENERAL MANAGER
George
JUNIOR MANAGER
Krishnan Namboodiri
Rajitha Susmitha
GENERAL RECORDS OF THE COMPANY
Daily Journals
Sales book
Purchases book
Ledger
Trading Account
Profit & Loss Account
Balance sheet
OPPURTUNITIES
The scope for Indian textile Industries is widening day-to-day. The share of Indian
textile industries in the international markets is expected to increase manifold in the coming
years.
THREATS
General recessions in the economy have its impact on the textile industry as well. In
order to cope up with the highly competitive and fashion sensitive International markets for
textile efforts to modernize the machineries on a continuous basis should be undertaken
without any hesitation.
Types of asset & liability
ASSETS
Free hold
Lease hold
Building
Plant & machinery
Electrical
Furniture
Office equipments
Computers
Vehicles
Canteen
Library
LIABILILITIES
Investment
Investments : 168 Nos. ―B‖ class shares of Rs 100/- per share in Malabar
Spinning & Weaving Employees Multipurpose Co-op. Society Ltd.
H.O. investment for revival
Investment by Head office
Grant from Govt of Kerala Investment for modernization by KSTC
Tax payment
License fee:24473.00
Total: 56029.00
Company car
Accommodation or reimbursement of rental charges
Medical bills reimbursement or free medical care for employee (extending for the
family as well and/ or children)
Subsidized meals. Employees are given discounted meal coupons at the office
cafeteria or given a fixed allowance for meals of their choice
Gifts in cash or kind during festivals
Every employee will be registered in Employee State Insurance Corporation.
The internal rate of return (IRR) is a rate of return used in capital budgeting to
measure and compare the profitability of investments. It is also called the discounted cash
flow rate of return (DCFROR) or simply the rate of return (ROR). In the context of savings
and loans the IRR is also called the effective interest rate. The term internal refers to the fact
that its calculation does not incorporate environmental factors (e.g., the interest rate or
inflation).The internal rate of return on an investment or project is the annualized effective
compounded return rate or discount rate that makes the net present value of all cash flows
(both positive and negative) from a particular investment equal to zero.
In more specific terms, the IRR of an investment is the interest rate at which the net
present value of costs (negative cash flows) of the investment equal the net present value of
the benefits (positive cash flows) of the investment. Internal rates of return are commonly
used to evaluate the desirability of investments or projects. The higher a project's internal rate
of return, the more desirable it is to undertake the project. Assuming all other factors are
equal among the various projects, the project with the highest IRR would probably be
considered the best and undertaken first.
Net profit & gross profit
Annual reports
APPLICATION OF FUNDS
Fixed assets
Gross block 38792390.57 38767587.58
Depreciation 20870884.85 21266722.97
Net block 17921505.72 17500864.61
Capital work in progress 28815410.97 20616464.18
Expenditure pending 53051.00 53051.00
allocation
TOTAL 46789967.69 38170379.79
Investments 16800.00 16800.00
-OBJECTIVES
-Software configuration
ESSL is used to assist the attendance system. Personal Attendance Monitoring System
(PAMS) is the most modern technology to record the attendance of the employees within the
organizations. Biometric finger initialization technology is adopted by the cotton mills.
Hardware Specification
eSSL-manufactured Hardware
Attendance Device
Access Control Device
Biometric Option - Fingerprint
Card Option - Proximity/MIFARE/HID
Sensor Type: Optical or Silicon Sensor
User Capacity – 1500-8000 (if only Fingerprint punch)
User Capacity – 60,000 (if Fingerprint punch Card)
Transaction Storage - 30,000 – 100,000
Display – TFT or LCD
Verification Time – 1 to 2 Second
Connection Options
Serial
Ethernet
Wireless Ethernet
GPRS
Intranet
Internet
Benefits
Identify and eliminate time abuses (break, meal, buddy punching, etc.)
Assign resources more effectively and reduce the time needed to schedule employees
All the accounts are computerized, when we switch over to computerized accounting
for first time. We should create all ledgers and enter opening balance and classify at this
stage. Just enter all the transaction in vouchers, click the journalisation, posting to ledger,
preparation to trail balance, financial statement etc, is done by the computer. The software
tally 9 version is used by the company.
Hardware
System analysis and designing was done by DGM of each units according to the
requirements of each user.
Each user was given a user name and password to protect the computer and all system
from usage of unauthorized persons.
System maintenance
Usually the contract was given to zenith, HCL, eSSL etc. Maintenance is of two
ways; without system replacement and with system replacement. Without system
replacement is done by internally and with system replacement is done by externally.
Features of system
The systems is protected from the attack of viruses using advanced antivirus program.
All systems are interconnected with each other by a server. So it is very easy for the office
staffs and all for entering the data and all.
Systems has more advantages compared with the disadvantages, the system help to
complete the work in stipulated time with precision. Because of the server all the computers
are inter-connected and so by this the staffs don’t want to rush out from office to office or by
system to systems. The only disadvantages is that it is machine and there is a chance of
problems which result in the loss of data
ADVANTAGES
The staffs don’t want to rush out from office to office or by system to systems.
DISADVANTAGES
It is machine
Identification of error
Every week there will be the inspection team who will be there for finding out the
errors of the system. If there has been any error occurred then soon they will be taking the
necessary actions to overcome the error.
Error handling methods
If there has been any virus threat or like that, then soon they will scan the system and
remove the virus from the system.
Cotton mills has leased lines of BSNL to facilitate their communications across
internationally. Microsoft windows 2003 operating system is using in the servers. There is
main server at Thiruvananthapuram and each units has their own local servers. Only
administrator can access the servers.
Database administration
Tally9, Microsoft Access are the two databases which is used in the company. The
administrator has the privilege to edit and handle the data in the database.
FINDINGS AND SUGGESTIONS
Findings:
Company is going at a loss of 24,57,55,920.25/- and we can see that the profit that
the company is earning is not even enough to pay the interest of the loans and all that
they have taken.
Malabar Spinning And Weaving Mills is the largest and the biggest cotton yarn
producing mill in whole Kerala.
Unions are always there for fighting there for some reasons and this will create delay
in the production process.
There are power failures or power cuts, there is no other option for power generation
or there is no generator so because of this production process will be interrupted then
and there.
Most of the people working in the mill are too old.
The company mostly concerned about the people and it’s not concentrating upon the
production.
SUGGESTIONS:
From the Study of this company I understood the functions and features of the
company. This company is improving their quality, goodwill, market value and they are
giving job opportunity so many people. They are the strength of the company’s growth. In
fact we can see that the company has modernised its machineries and all and it’s the biggest
cotton mill industry in whole Kerala. With all most modern facilities.
The institutional training at Malabar Spinning & Weaving Mills Calicut helped to
have a good knowledge about how a company operates and the consequent focuses relating to
the business activities. In the short span of training the company management provides me a
good exposure to the working and management work out in the detail run. It enhanced about
plants production process in details ,which paved way for rich experience in plant supervision
it also provide with information regards the exports financial and human resources activities
and documentation in the organization ,which was new area entrance for me.
The training has helped to know the various delegation s that is found in the
organization and responds ability each delegates have the training has given a deep sense of
understanding how an organization takes efforts in bringing in product as an effective one
and how it can be good in competing with its competitors.
The organizations growth decides their tireless effort in bringing it up .The expansion
and establishment of the organizations in various places and in various forms denotes their
financial efficiency and capabilities.
VI. BIBLIOGRAPHY
TEXT BOOKS
WEBSITES
www.wekkipedia.com
VII. APPENDIX
KSTC: Kerala State Textile Corporation