INDUSTRY PROFILE

According to Webster`s dictionary, dyeing is the process of coloring fibers,

yarns or fabrics by using a liquid containing coloring matter for imparting a
particular hue to a substance. There are there basic methods of imparting a
particular hue to a substance. The first is by staining an item, a temporary
means of collection where the color is rubbed or soaked into an item without
the benefit of some sort of chemical fixative to preserve the color. The next is
the use of pigmentation, wherein the color is fixed to the surface of an object by
another adhesive medium. A true dye is when the color a substance is
deposited on another substance in insoluble form from a solution containing
the colorant.

Dyeing was practiced in Egypt, Persia, China, and India thousands of years
ago. Before 1856, natural materials derived from insects, plants, shellfish, and
minerals were the only known sources of dyestuffs. These sources included the
root of the herb madder for red dye and the indigo plant for blue dye. In the
early days of the Roman Empire, garments colored with Tyrian purple, a dye
derived from a shellfish of the Mediterranean Sea, were worn by the imperial
family and the nobility. As late the 4 th century ad, cloth colored with Tyrian
purple was the symbol of royalty.

The art of dyeing was stimulated in the 13 th century by the discovery of achil, a
purple dye made from a species of lichen. Northern Italy, where the discovery
was made, becomes the center of dyeing in Europe. In the 16 th century,
explores brought back from the Americas such of dyeing as cochineal and
logwood. Other important sources of natural dyes included quercitron, weld,
fustic, brazilwood, safflower, and indigo plants.

In 1856 the first synthetic dye, mauve, was derived from coal tar. Mauve was
developed by British chemist William Henry Perkin so that it could be produced
easily on a scale. Since then a great number of synthetic dyes have been
developed, and the use of natural dyes has almost ceased.

COMPANY PROFILE

With a wide range of products which are supported by world class production,
quality control and research facilities, Joy Polyfab Pvt. Ltd. Is rapidly
emerging as one of the fastest growing exporters of fabrics with a strong global
presence.

Founded in 1993, it has since grown into a vertically integrated organization

engaged in Bleaching and Dyeing of a wide variety of fabrics like 100%Polyester,
Viscose and Linen. It is a part of a Group company which is into the business
of Weaving, Dyeing, and Stitching Exports since 1984.

Our Plant is equipped with a full range of 'State of the Art' machinery which
has been sourced from the best manufacturers from around the world.
3

In our Dyeing department, we have equipments like Hydraulic Jiggers, Jet

Dyeing Soft flows, Maxi jiggers, Singing, Desising and Mercerizing machines.
The Pad batch dyeing machine is from Kuster of Germany which facilitates
dyeing of long lengths of 100% cotton from 2000 to 5000 meters without center
of salvage variation.

The Finishing section is equipped with zero-zero finish five chambers Hotair
Stentor, 16 cylinder drying range machine, brushing machine, Peaching
machine, and five bowl calendar machine and decatise machine.

All these machines are operated and maintained by a team of well- trained and
highly qualified operators and engineers to ensure the best performance.

The plant has a monthly capacity of 2.5 million meters, of which 1.5 million
meters consists of Synthetic Dyeing and Cotton Dyeing.

The Manufacturing range also consists of Clothing for Men, Ladies and Kids
made from 100% Polyester, P.V. & P.C. Fabrics. These come in a variety of latest
designs and patterns.

We understand that consistently delivering quality products is the only way to

earn the trust and respect of the global community. At JOY, committed towards
quality is ever present right from the development to the procurement of rawmaterial to the dyeing and finishing of the fabrics.

Our extra push on quality control enables us to produce world class suiting
sheeting fabrics. We are especially renowned for the whiteness of our fabrics.

Building strong and long lasting customer relationships is one of our key
strengths. Customer satisfaction is the life force which drives our organization.
It has always been our conscious effort to provide the customer with the best
possible quality at the most competitive rates with a constant emphasis on
innovation and reliability.

We have the best packaging facility as demanded by our international

customers. The goods are checked to be totality free of any kind of defects
before packing them. We also have a huge warehouse which can securely store
huge amount of goods.

SOCIAL RESPONSIBILITY
Responsibility towards society has come as naturally to joy as responsibility
toward its customers, its stakeholder and the environment.
As a responsibility company, joy has involved in a wide variety of social and
charitable endeavors both in the urban rural areas of India.
Joy has earmarked funds towards infrastructure-development in its region,
which covers requirement such as schools and hospital. Assistance is also
planned for public health centers in the area.
In its region, Joy has been providing employment opportunities to the needy
according to their skills, and assistance to youngsters.
Joy also organizes regular health camps in its region with the help- of
voluntary organizations. In one such instance, a yoga camp attended by over
25000 people was organized in Indore.In its towards social causes, Joy has
placed utmost importance on its employees, acknowledging the fact that
charity begins at home.
The company`s employees enjoy a host of benefits deigned to promote a better
life like free housing, free medical facilities, interest-free loans, free
transportation to school children and subsidized food.

FUTURE PLAN(VISION)
1. Increasing Production with Latest Machinery.
7

2.
3.
4.
5.
6.

Technology up gradation.
Improvement in quality.
Reduction in damage Percentage.
Setting a New Cotton Plant.
Weaving plant.

COMPANY DETAIL

PARTICULARS

INFORMATION

Name:

JOY POLYFAB PVT LTD

Size of the
organization:

Small Scale Industry

Director:

Mr. Bhupendra golkiya

Mr. Arvind golkiya
Mr. Sanjay Savani

Chartered
accountant:

Mr. Manoj Shah

Banks:

Oriental Bank of India(OBI)

Transportation
Sources:

Tempos, trucks

Area of the
Company:

6000 Sqr.Mtr.

Incorporation
Date:

15th August 1998

Annual
Turnover:

13 Crors

Registration
office:

JOY PPLYFAB PVT LTD

Plot No.1801\2, 3rd Phase,
GIDC, Vapi 396195,
Gujarat, India

Factory:

JOY PPLYFAB PVT LTD

Plot No.1801\2, 3rd Phase,
GIDC, Vapi 396195,
Gujarat, India

E-Mail:

info@joygroup.in,
joypolyfab@yahoo.com

Tel:

+91-260-2421890

Fax:

+91-260-2435290

10

COMPANYS EXECUTIVE SUMMERY

NAME

DESIGNATION

Shri Pershotambhai
Golkiya

Promoter

Shri Bhupendra
Golkiya

Director

Shri Arvind Golkiya

Director

Shri S.P. Svani

Director

Shri Umesh Maroliya

Production
Department

Shri Rajesh Tundon

Marketing
Department

Shri Manoj Shah

Finance &
Accounting

Shri Rajesh Patel

Personnel & HR

Shri Arvind Golkiya

Collection

Shri Yogesh Golkiya

Purchase

Shri Pravin Patel

Maintenance &
Engineering

Shri Umesh Maroliya

Dress & Suiting

Department

Shri Somnath Kakde

Laboratory

Shri Jayram

Packaging &
Finishing Goods
Store

Shri Jayram

Packaging &
Finishing Goods
11

Store
Shri Raju Patel

Cashier

12

ORGANIZATION STRUCTURE OF JOY

Managing Director

Production

Marketing

Customer
Relationiio

Collection
& Payment

n
Production
manager

Maintenance

Purchase

Store
Keepin

Color & Chemical

Purchase

g
Assi.Manager

Finance

Purchase

Store
Keepin
g

Assi.Manager

Insurance

Time
Keeping
Account

Banking

13

14

INDUSTRIAL MARKETING

Different management theorists have defined marketing in many different

ways. In the words of Mr. Philip Kotler, Marketing is a societal process by
which individuals and groups attain what they need and want through
creating, offering, and freely exchanging product and services of value with
others.

While the basic tenets of consumer marketing are equally applicable to

industrial marketing, the composition of industrial market is uniquely different,
as there are different forces that affect industrial demand.

Thus, Industrial marketing consists of all activities involved in the marketing

of product and services to organizations that use products and services in the
production of consumer or industrial goods and services, and to facilitate the
operation of their enterprises.
Industrial Marketing Committee Review Board.

Hence, industrial marketing managers must react differently to changing

markets, develop products to meet those changes, and market them in a
uniquely specialized ways to sophisticated customers while maintaining
corporate objectives and profits. Thus, industrial marketers face many unique
market situations not normally encountered to the consumer market.

Market
The common usage of market means a place where goods are bought or sold. In
its strict meaning market need not necessarily mean a place of exchange.

Marketing
Marketing is concerned with selling but now a day the concept has enlarged its
meaning. We know that a product is provided with the aim of sale. The aim
producer totally depends on marketing. Without marketing no unit can run. It
covers marketing research, new product development and so many other
important functions.
15

Marketing is the process of discovering and translating consumer needs and

wants into product and service specifications, creating demand for these
products and services and then in turn expanding this demand.

STRUCTURE OF MARKRTING

Marketing
Marketing
department
department

CUSTOMER
CUSTOMER
RELATION
RELATION

Customers
Customers

Customers
Customers

PAYMENT
PAYMENT

Customers
Customers

COLLECTION
COLLECTION

Customers
Customers

Customers
Customers

CLACIFICATION OF PRODUCT
16

JOY does job work. Its customers give them Grey. Grey can be a shirt or dress
material. Then on Grey they do dyeing.

Type of Fabric Manufactured by us

100 % Cotton ( All Type )

100 % Viscose & Rayon Fabric
100 % Polyester Fabric
Cotton Viscose and its blends Linen
Cotton Nylon and its blends
Acrylic and its blends

17

18

Type of Dyeing

Disperse Dyeing
Reactive Dyeing
Vat Dyeing
Double Dyeing
(Disperse+Reactive)
(Cationic + Disperse)

PRODUCT

SHIRTING

SUITING

DYEING

DYEING

DOUBLE
DYEING

REACTIVE
DYEING

DISPERSE
DYEING

VAT
DYEING

DOUBLE
DYEING

REACTIVE
DYEING
DISPERSE
DYEING

VAT
DYEING
19

20

SALES VOLUMES & SALES FORECASTING

Sales are anything that a company offers for the purpose of selling or in
exchange for a specified value, generally in monetary terms. The sales volume
tends to be the total worth of goods that a company sells in a financial year.
The sales tend to be one of the most supportive tools in order to the
organizational goals hence, sale volumes of any company is very important
part.

SALES
VOLUME
METER
DAY

2007

2008

2009

SALES

135,256,336

141,648,235

149,273,679

CLOSING
STOCK

1,965,226

2,786,794

1,473,313

OTHER
INCOME

134,653,222

144,154,716

152,310,866

PROCESSING
CHARGES

132,223,679

135,033,624

140,981,767

TOTAL

404,098,463

423,623,369

444,039,625

IN
PER

21

Year

22

The Sales Volume Of JOY has increased compared to its previous years. Thus,
it can be said that some extend the Company has been able to move towards its
goals more accurately.

But only sale itself not important along with is also its forcasting. Sales can tell
the current position of the business but without forecasting the company wont
be able to tell if it will be secured equally in the near future also or not.

Forecasting is the prediction of what will happen in the future. A forecast of

product demand is the basic of most important planning decision. However,
forecast is an uncertain process. Management generally tries to forecast
demand / sales with as much accuracy as possible, which is becoming
increasingly difficult to do.
Forecasting of any product is generally done taking in mind two components:
1.Time Frame.
2.Demand Behavior.

In Time frame we forecast on basic of the time consideration, whether we want

the forecast to be short ranged, medium one, or long. In Demand Behavior, we
forecast keeping in mind the various demand situations like the trend followed,
any random variations, cyclic patters, seasonal patterns, etc. JOY presently
process 1.5 lakhs meters per day now they are planning to increase their
processing capacity to 2.5 lakhs per day.

23

CUSTOMER SEGMENTATION & TARGET MARKET

Customer segmentation is the practice of dividing a customer base into groups
of individuals that are similar in specific ways relevant to marketing, such as
age, gender, interest, spending habits, and so on. Using segmentation allows
companies to target groups effectively, and allocate marketing resources to best
effect.

According to an article by Jill Griffin for Cisco Systems, traditional

segmentation focuses on identifying customer groups based on demographics
and attributes such as attitude and psychological profiles. Value based
segmentation, on the other hand, looks at groups of customers in terms of the
revenue they generate and the costs of establishing and maintaining
relationships with them.

A marketer can rarely satisfy everyone in a market. Not everyone like the same
goods. Therefore, marketers start dividing up the market. They identify and
profile distinct group of buyers. Market segments can be identified by
24

examining demographic, psychographic, and behavioral differences among

buyers.

JOY market segments by geographic and demographic variables. Geographic

variables such as region, city, climate etc. JOY select whole world for selling its
fabrics and vapi city for production. Demographic variables are age, gender,
income, education etc.JOY manufactured of clothing for men, ladies and kids.
Also, JOY produce dyeing as per the requirement of customer so it
differentiates for men , women and kids in some special needs.

25

UNIQUE FEATURES OF PRODUCT

JOY enjoys a good market reputation. JOY is known for its quality & price. JOY
is known for over print, padding discharge & dyeing & linen dyeing. JOY is also
known for its color combination, designs & matching. They keep a sharp eye on
the market trend.

GEOGRAPHIC
LOCATION

INTERNATIONAL

NATIONAL

EAST

WEST

NORTH

SOUTH

WEST

NORTH

SOUTH

EAST

DEMOGRAPHICS
(a) Age:
Different people have different taste and preference. JOY
needs of all age of male and female.

cater to the

(b) Gender:
PRODUCT
26

SHIRTING

SUITING

DYEING

DYEING

(c) Occupation:
Students, Housewife, Professional etc.
(d) Income & Social class:
Upper Middle Class & Upper Class.

PHYHOGRAPHICS:
Lifestyle: Culture oriented.
Personality: Decent.

BEHAVEIOURAL:
Occasion: Regular.
User Status: Regular User.
Usage rate: Heavy User.

CUSTOMER ORDER PROCESSING

COLLECTION OF ORDER

ANALYSNG
LEVEL

THE

PREPARATION
FORM

PRESENT

OF

STOCK

PROGRAMME

27

PRODUCTION PROCESS

PACKAGING

TRANSPORTATION

COMPETITORS

Competition includes all the actual and potential rival offerings and
substitutes that a buyer might offer.
-Philip Kotler
However, the market approach to competition states that, Competitors are
companies that satisfy the same customer need.

JOY is a known for its quality as well as its price. It caters only to domestic
need. Being a part of growing market JOY faces a tough competitor in the
market. With the large number of competitors some of the major competitors
are:

Mahalaxmi (Mumbai)
Dhanlaxmi (Mumbai)
Chiripal (Ahmadabad)
Creative Garments (Vapi)
28

These companies tend to compete with JOY in almost its entire product. But
among all the Direct Competitors the most challenging competitors lies in vapi
itself like G. but as such no survey has been done to known the market share
of different dyeing houses.

COMPARISON OF 4PS OF VARIOUS PRODUCTS OF JOY WITH

COMPATITORS

Marketing mix is the policy adopted by the manufacturers to get success in the
field of marketing. Those days, when goods were matched with the market have
gone. Marketing mix is the term used to describe the combination of 4 inputs
which constitute the core of companys marketing system the product, the
price structure, the promotional activities and the distribution (place) system.
These are popularly known as, 4ps.
A brief description of four elements of marketing mix of joy :

29

Product

Promotio

Marketing

mix

Price

Place

Product
A product is anything that can be offered to a market that might satisfy a want
or need JOY produce 100% polyester, P.V. & P.C. fabrics for its customer.
Other companies do not have so large range of product width and length. JOY
produces more qualitative products than the competitors. JOY also research
and produce new dyeing and patent them. Such disperse dyeing, reactive
dyeing, vat dyeing, and double dyeing (disperse + reactive).

Price
The marked or announced amount of money asked from a buyer is known as
basic price of a product. JOY use value pricing method for its products. In this
method, JOY charging fairly low price for highly qualitative product, which
its competitor cannot done. JOY charged low price than its competitors because
JOY less expense in promotional activity and for distribution. JOY charged low
price and its main objective is provide TO 100% polyester, p.v. & p.c.fabrics.

Promotion
Marketing communication consist of communication marketing activities
through various forms of promotion that is personal selling, advertising,
publicity and public relationship, sales promotion etc. together called
30

promotion mix JOY does not do more expenditure for promotional activities like
other companies JOY do zero level marketing than also JOY easily sale its
medicine and its dealer largely expand in all National & international level.

31

Place
Place means the decision by which company transfers their product, location,
inventory handling, warehousing, storage facility, transportation etc JOY is
located near the nation high way so it can transport and get material easily.
JOY has direct contect to exporter and customers than its competitors.
Competitors like MahaLaxmi, Chiripal Pvt. Ltd., DhanLaxmi Ltd. have not so
widely develop distribution network in Gujarat.

COMPETITOR VALUATION ON BASIS OF 4Ps

The 4Ps namely; Product, Price, Place & Promotion are asset of marketing tools
that any company uses to pursue its marketing objectives in the target market.
Each P, if used successfully can deliver a special customer benefit, which can
be very beneficial in a highly competitive environment. To these 4Ps a new P
(packaging) has also been added and is said to be the 5 th P, which affects
market also now a days to a great extent.

As seen earlier, in the current situation the greatest direct competitor of JOY
tends to be chiripal (Ahmadabad) thus; it would be better if comparisons were
made with respect to chiripal only. The comparisons of 5 Ps reveal several good
as well as some negative aspects of JOY thus, showing the fields where it can
improve itself and have a better market share for itself.

Competitor valuation on basis of the Ps

Marketing
Tools (Ps)
Product

Price

Place

JOY

CHIRIPAL

Good
quality
with
higher
product
mix.
They believe in
use
of
new
technology
for
their product.
Comparatively
slightly
higher
then A
Vapi

Good quality

Slightly
then JOY

lower

Ahmadabad
32

Promotion

Spends
higher
comparatively

Packaging
(5th P)

More flexible

Large
variety
serves
it
indirectly
Flexible

33

PRICING POLICY
JOYS pricing policy depends on:
1. Manufacturing cost
2. Marginal cost
3. Competitor Rates
4. Competitor Quality
5. Market Requirement
6. Customer Focus

PROMOTION & ADVERTISEMENT POLICIES

Advertisement
Advertising is any paid form of non-personal presentation of ideas, goods or
services by an identified sponsor. Advertisement is used to lay a foundation for
the sale by providing information on the company and its products and by
reaching unknown and inaccessible buying factors.

JOY has a very strong presence in the global market.

This is due to our policy of providing the best possible
products at the most competitive prices. We also keep
up with the latest trends and technologies from
around the world which has further boosted our
reputation as exporters. Our channel partners have
also constantly provided us positive feedback and
suggestions which have helped us to grow.

REPORTS IN MARKETING DEPARTMENT:

1. Daily Grey inward report
2. Daily dispatch report
3. Daily payment collection report

34

DOCUMENTS RELATED TO SALE:

1.Challan
2.Gate pass
3.Invoice
4.Dispatch Order
5.Price list

35

PRODUCTION
Professor William Graham of Yale University made the following statement
Wealth comes only from production. The meaning of production follows from
foregoing definition of wealth. With reference to goods we should say that
production is the fabrication of physical object through the use of men,
material and equipments whereas with reference to services it can be said,
Production is some discharge of the function which gives some utility.
Unfortunately many individual and organization continue to apply the term
production solely to the manufacturing activity. But a fairly recent ton is ton
substitute the word operations for production.

PRODUCTION MANAGEMENT

Management refers to the establishment and attainment of objectives. Goals

are stated. Mans talents and material are available. The basic production
resources, which are commonly referred to as SIX Ms men, materials,
machinery, methods, money, and market are brought together to achieve the
stated goals. These resources are processed, planned. Organized, cocoordinated and controlled with a view to achieving the end result.

Both directly and indirectly management keeps a close watch over the
materials with the help of which people who are at work, accomplish their
assigned job and thus help in attaining the stated goals of the enterprise.

36

37

Production is the process of converting the raw materials and other inputs into
the products for further production or the finished goods or services so that
the utility of inputs is created or enhanced and the needs of the consumers are
satisfied. That is consumer goods, industrial goods, services of transport,
medical treatment, education, banking, post and telegraphs, insurance etc. so
in simple meaning the management of the production process is called as
production management.

Production management means creating and maintaining an environment in

which individuals working together in groups willingly contribute their best to
produce the specified goods and services by optimum utilization of raw
materials and other inputs so as to timely satisfy the needs of the customers.

Good Production management is essential for every organization and it is

important in following ways,

It
It
It
It

helps to satisfy the need of customer timely.

increases the productivity of organization.
gives better satisfaction to the employees.
satisfies the investors by increasing return on investment and
capital appreciation.
It satisfies the community by welfare and development activities.
It satisfies the suppliers.
It benefits to whole nation.

38

39

PRODUCTION HOD

(Umesh Moraliya)

Shirt

`Dress

New Dyeing

Dyeing Master
Assistant Dyeing Master
Supervisor
Asst. Supervisor

Jet

Stenter

Padding

Drumming

Incharge

Operator

Helper

Jobber

(For Dress and New Dyeing)

40

41

PREPARATION OF PRODUCTION PLAN FROM SALES PLAN

Production planning is that function of management which decides about the

resources that will be required for future manufacturing operations and of
allocating these resources to produce the desired output at right time, in right
amount, of required quality and at minimum cost.

Production planning is the planning of how much produce, Requirement of

human resource and finance. It is also planning of quality standard and raw
materials requirement etc. production plan is preparation of guiding plan
before starting production plan involve when, what, how and why to produce
goods.

In JOY normally production plan is prepared from the sales or demand for the
product of company. Starting point of production planning is dispatch
department. Dispatch department supply various products of JOY to the
dealers. From the information of dispatch department, production department
decides about manufacture various products as per requirement and for this
they prepare production plan.

In JOY, production planning is include planning of material requirement,

requirement of manpower, capacity requirement etc.

42

43

Material requirement planning

Material requirement planning is the first of the production planning in any
company. In JOY, production manager is check the availability of require inputs
or raw material. If raw material is not in stock then give purchase order or if it
is in stock, production manager do next planning of manpower.

Manpower planning
For achieving successful result of production planning, it is advisable to make
manpower planning in advance. In JOY first they decided how much labor
required producing desirable quantity. If there is shortage of manpower, they
hire casual or part time labor.

Capacity requirement planning

Capacity requirement planning is a technique to determine what personal and
equipment capacities are required to meet production objectives. In JOY, they
make CRP, various operations and activities are assigning to various
department. If capacity is inadequate they adjust it by some addition labor or
over time.

Maintain quality standard

In JOY, there is separate department called quality assurance department
which is check quality of raw material finished product and semi finished
articles on company standards. They try to improve quality management
system for better customer satisfaction and provide qualitative medicine to its
customers.

44

Inventory control
Since entire material requirement planning is done on the basis of production
plan, ultimately inventory level depends on accuracy of production plan. In this
industry, they use first in first out method for inventory control.

MATERIAL REQUIREMENT PLANNING

Material requirement planning is a technique for determining the quality and
timing for the acquisition of dependent demand items needed to safety master
schedule requirements.
In JOY, for preparation of material requirement planning three inputs are used
which are as follows:

Master production schedule

Mps is based on forecast of various items. MRP accepts practically possible
master production schedule quantities of various items as quantities of items
to be manufactured. It further calculates what the requirement of various raw
material and inputs is.

Inventory status file

All the quantities of various items in Mps is never considered for MRP process
it is always considered after deducting present inventory levels of various items
and pending purchase orders for this purpose, it is necessary to take data from
inventory status file of various items.

Bills of material
It is a database, which specifies relationship between raw material and
outputs. This document is necessary to convert production quantities of
finished products into requirements of various raw materials, parts,
components and sub assemblies.

Bills of material shows each of the materials, parts or sub assemblies by

unique part number, which facilitate processing by in to price and also
contents the quality of parts or material require per unit of end product. Bills
45

of material have a series of level each of represents a stage in the manufacture

of the end product.

Level 1: Representing final assembly or end product.

Level 2: Shows parts and sub assemblies when end product is
the first desmemtated.
Level 3: Result of desmentating the sub assemblies of level 1 in
form of part and father sub assemblies.

46

In JOY POLYFAB the sales plan is prepared on the basis of last years sales.
Once, the reasonably accurate sales plan is prepared, the actual production
planning starts. Once the sales plan is prepared it is conveyed to the
availability of raw material, tools and resources required for the production.
Here the present stocks of finished goods are also taken in to consideration.

After the available stock level of finished goods is checked, planning

department issues program from to the production department. This program
from consists of the description of various articles to be produced on different
machines.

CONVERSION OF PRODUCTION PLAN INTO MATERIAL REQUIREMENT

PLAN AND ULTIMATELY INTO PURCHASE PLAN

As soon as program form is received from the planning department, the various
materials in the stock are checked by the production department head. He then
breaks the final requirement into various raw materials. He ensure the
availability of various raw materials which are required plan is prepared, the
present stock level of raw material is also taken into consideration.

There after, the list of unavailable raw materials which are required in the
production of final product is prepared and it is sent to the purchase
department.

On the basis of this list sent by the production department, the purchase
carries out its further planning and prepares purchase plan out of it.

47

48

Analysis of plant location

It is a function of determining the production unit should be located for most
economical and effective operations.

The points for which the decision of plant location is taken are as follows:

New business
Expansion not possible at the same site
Economic factor (land cost of old factory becomes high so by selling
it owner get large economic benefit)
Expansion opportunities needs more branches
Sudden development because of natural calamities
Special circumstances

The main objective of JOY is to maximize the profit through the minimize cost
of production. This objective can be achieved only when the plant is at the right
place where all kinds of production facilities are available.

Selection of plant location considering various factors:

Depending upon area availability

Availability of raw materials
Water supply availability
Gas supply availability
49

Cost of land
Taxes liberalization
Government other incentives
Nature of production operation

50

ANALYSIS OF PLANT LOCATION

1. Organization: JOY POLYFAB Pvt. Ltd.
2. Existing factory Building plan: Plot No. 1801/2 3rd Phase, GIDC, Vapi.
3. Area: length *Breadth =6000 Sq.Mtr.

PLANT LAY- OUT

Plant lay-out is configuration of departments, work station and equipments in
the production system or in the conversion process. Plant lay-out is the
arrangement of machinery, equipments and facilities such as receiving and
shipping departments, tool rooms, maintenance rooms, inspection cabins,
stores, plating shops, heat treatment chambers, trolleys, cranes and other
handling equipments, employee amenities like toilets, canteen, rest and change
room, parking facilities etc. so as to ensure smooth and quick movement of
materials from raw material stage to finished product stage with minimum
material handling, quality of operations, good communication etc. at the lowest
possible handling cost. It includes arrangement of new plan and also revision
in existing lay-out.
Plant layout is the physical arrangement of main production departments,
technical utilities personnel utilities, offices& location of machines within
different departments.

There are various types of lay-outs are as follows:

Process lay-out.
Product lay-out.
Fix position lay-out.
Cellular manufacturing lay-out.
Combination lay-out.
Service lay-out.

PROCESS LAYOUT
In JOY, the plat lay-out is process type of plant lay-out. This company
manufactures many products on continuous bases and machines are for
special purpose. In this lay-out the machines or facilities are arrange sequence
of an operations require by a particular product.

51

A process is a group of related tasks with specific inputs and output. Processes
exist to create value for the customer, the shareholder, or society. Process
design defines what tasks need to be done and how they are to be coordinated
among functions, people and organizations. A process design depends on the
type of production system the company wants to follow. JOY POLYFAB has a
combination of two types of production systems.

52

i.
ii.

Job Shop Type, and

Batch Production System.
Job shop type production system, each product is totally unique. Each
customer orders a special product to suit his or her application. Hence it can
be said that as JOY POLYFAB provides totally customized products as per the
customer specifications, it follows an IPS and have a Job Shop Type one.

Once the process system has been formed, now production design can be
discussed. As the company doesnt produce a single product it must adopt a
layout in which the maximum products can be created with minimum changes
in the layout. Hence the company created a layout for itself in which the
company needed to change only its material input and the duration of
processing them but not any change in the pattern of machinery usage or the
usage of any extra machinery.

53

PRODUCTION PROCESS
GREY

STITCHING

JET (Bleaching/dyeing or Scouring)

MERSERIZING & NEUTRILIZING (Washing)

PADDING(Dyed in 2 or More diff. color)

WASHING

STANTER
(Finishing)
ssssSTANTERSTA
NTER(fINISHING
FOLDING
(Checking)
ssssSTANTERSTA
NTER(fINISHING
PACKING

54

DISPATCHING

TERMS RELATED TO PRODUCTION PROCESS

GREY
Woven or Knitted Fabrics as they leave the loom or knitting machine, i.e.
Before any bleaching, dyeing or finishing treatment has been given to them.
Some of these fabrics, however, may contain dyed or finishing yarns. Note: in
some countries, particularly inn the North American continent. The term greige
is used for Woven goods. The term loom state is frequently used as an
alternative. The linen and trades. The term brown goods is used.

55

JET
On jet fabric that is on the grey stage or after drumming is scoured, bleached
and white or dyed. Jet is

1. A machine for dyeing fabric in rope form in which the fabric is carried through
a narrow throat by dye-liquor circulated at a high velocity.
2. A machine for dyeing garments in which the garments are circulated by jets of
liquid rather by mechanical means.

Scouring, an operation to remove the sizing and tint used on the warp yarn in
weaving and, in general, to clean the fabric prior to dying. Mostly 70 to 80 %
fabric required jet process. Very delicate quality of fabric like nylon does not go
on jet.

JET MACHINE

HORIZONTAL JET

VERTICAL JET

56

CHEMICAL: For Scouring and bleaching chemical are required and for
whitening process white R is used.
E.g. dani - 6 kgs 200gms

Basic temperature 1200C and whole time is 30 minute. Rate of rise 0.50C to 10C
per minute.

{Figure: VERTICAL JET MACHINE}

Vertical and horizontal type of machine differ in water liquor quantity, process
will be different that is results will differ, color chemical consumption also
differ.

{Figure: HORIZONTAL JET MACHINE}

57

For quantity like laser that require highly weight reduction process for that a
latest machine called Sofleena is used. For shiffon-based cloths, which require
more wrinkle effects, horizontal jet machine is required costing is less in
vertical jet and it requires less water liquor ratio and chemical. Companies like
Sridhar, Devrekha, Sun Engineering etc manufacture jet machine.

STENTER

Stenter is an open-width fabric-finishing machine in which a pair of endless

travelling chains maintaining weft tension holds the selvedges of a textile
fabric. Note 1: attachment may be by pins (pin stenter) or clips (clip stenter).
Note 2: such machines are used for: (a) drying, (b) heat-setting of thermoplastic
material, (c) fixation of chemical finishes.

Heat setting is the process of conferring dimensional stability and other

desirable properties (wrinkle resistance and improved heat resistance) by
means of either moist or dry heat. This process is necessary. Fabric is ready
after the heat setting process. For heat setting process acids are used. E.g. for
dani material if 4 chamber stenter machine is used and if the temperature is
170 C then speed is 50 meter per minute.

After washing process the fabric is again comes on stenter machine for
finishing process. The finishing is done for getting soft and stiff feeling. Using
finishing chemical at particular temperature and speed does finishing.
Chemical like ultra soft, lax soft is used for getting soft finishing on Dani type
of fabric.

Stenter machine differ in number of chambers different type of fabric required

different number of chambers. Generally in vapi for synthetic material like
nylon and polyester, which is used for making sarees and dress materials 3 to 5
chamber stenter are used. For heavy material like cotton and shirting and
suiting etc. 8 to 10 chambers stenter machine are used.
58

For chemical application mangle device is required which is one part of stenter
machine. Mangle is one type of roll through which fabric is passed so that it
gets chemical penetration for finishing effects. A machine whose purpose is to
express liquid from moving textile by passage through a nip. The textile may be
in rope from or in open width, and the mangle may consist of two or more
rollers (bowls) running in contact.

59

{Figure: Mangle Machine}

PADDING

Impregnation of a substrate with liquor or a paste followed by squeezing,

usually by passage through a nip, to leave a specific quantity of liquor or paste
on the substrate. For discharge print padding is used for shade dyeing padding
is required. It is a process in which the grey could be dyed. It could be dyed in
2-3 different colors at the same time.

Dyeing station & color spreader: when the grey reaches dyeing station one
person continuously spreads & pours color to the color spreaders, which
further spreads it on the cloth.

60

61

UTILITY
Utility department is what a respiratory system is to a human body. Without
utility the plant cannot operate. It includes EFFLUNT TRETMENT PLAN (ETP),
DM WATER, SOFT WATER PLANT, AIR COOLING UNIT, N2 PLANT, POWER
GENERATOR PLANT, COOLING TOWER, BOILERES, AIR COMPRESSOR,
DISSICANT DRYER and CHILLERS.

DM WATER: DM water means totally dematerialized water is free from any

cautions or anions. Hence the conductivity if the water should be zero. In this
plant it is 0.5 micro se mens. Finally this water is used mainly in chemical lab
and textile lab.

SOFT WATER PLANT: Soft water is essentially free from carbonates and
sulphates. This plant mainly consist of an activated carbon filter in which
carbon beads with sand are packed in a tower through which the raw water is
pumped, this carbon essentially absorbs any undisclosed solids, impurities
from the water. The soft water is used for drinking purposes dyeing
preparation.

EFFLUENT TREATMENT PLANT: This plant is used to treat chemical water,

which comes from dyeing and poly plant. The treated water is then used for
gardening purpose or released in the Dhahran River.

POWER GENERATION PLANT: The plant uses of diesel generator each of 1800
KV. These generators are used to generate power in the plant. Modern petrifies
takes only 5% of the electricity from the government rest is generated by these
diesel generator sets.

AIR COOLING SYSTEM: The unit supply conditioned air for auxiliary area. It
consists of six AHU (air handling unit) each unit consists of chilled water
control loop piping. Supply air fan, filter of 25 micro size, cooling coil, and
supply and return ducting & dampers, exhaust fan.

COOLING TOWER: It is natural draft cooling tower of cross flow type. The
purpose of cooling tower is to supply cool water to in chillers, compressors,
62

dryers for the process, plant in poly and spinning department at required
pressure and temp.

BOILERS: This plant uses three boilers to supply steam at different pressure
for process requirement. It supplies generated steam to poly department,
spinning department, dyeing.

63

AIR COMPRESSOR: Air compressor is required to increase the pressure of the

air used. It is used to supply the compressed air required process.

MATERIAL HANDLING EQUIPMENTS

The final phase of the layout analysis, as related to production departments,

calls for the analysts making two decisions simultaneously. First, he must
decide where the physical facilities are to be located. At the same time, he must
decide what kind of materials handling equipment is to be used so that space
can be provided for this equipment. The method of handling materials can be
decided upon only after two things are known. Once is the kinds and amounts
of material to be transported. The second is the locations from and to which
materials are to be transported. These locations, however, will be determined by
the locations of the respective workstations. Although there are hundreds of
different kinds and types of handling equipment, all can be placed in three
major categories;
1. Conveyers,
2. Industrial trucks, and
3. Cranes and hoists.
4.

Platform Truck

64

65

Electric Stacker

Drum-Trolley

66

Luggage trolley

67

TYPES AND CLASSIFICATION MATERIAL HANDLING

Material handling is defined as controlled movement of material, from receipt,

through storage and production and up to the shipment of finished product. As
definition suggests it is concerned with storage and internal movement of
following type of material.
Raw material
Work-in-progress inventory
Finished product
Surplus and waste
Capital equipments

JOY used only solid and liquid raw material. So we can classify the material
handling equipments of JOY in following basis:

Classification on the basis of form of material

According to this classification there can be three broad categories, solid
material, liquid material and gases.JOY use hand carts, trolleys like DRUMtrolly and LUGGAGE -trolly, trucks with container and manual handling
system for solid material and pipelines and barrels for liquid material.

Classification as per path of movement

JOY use different equipments as per path of movement. Whether movement is
vertical or horizontal, whether it is a fixed path movement or variable path, the
equipments are different for each purpose such as hand carts can take variable
path and pipelines are for vertical movement of material.

Classification on the basis of degree of automation

There are three categories according to this method of classification. First, fully
automatic handling equipments like robots. Second, semi automatic handling
system like conveyer belt. Third, manual system like hand carts and trolley.JOY
uses only third category which is manual system.

68

Classification on the basis of source of power

Equipments can be electrically powered, powered be any fuel and manually.
JOY uses all these type of equipments such as boiler and machines are
electrically powered, truck are use diesel and hand carts are manually powered

69

INVENTORY CONTROL SYSTEM

Inventory control is the means by which material of the correct quality and
quantity is made available as and when it is required with due regard to
economy in the storage costs, setup costs, manufacturing costs, purchase
prices and working capital.

As inventory is an essential part of any organization. Systematic management

and control of inventory for all the items is a challenging job. JOYS main
objectives of inventory control are:

To maintain investment in inventory at the lowest level

To supply the products to its user as per their requirement at right time.
To keep inactive, waste, scrape and obsolete items at the minimum level.
To minimize holding, replacement and shortage cost of inventory at minimum
level.
To maximize the efficiency in production.

Large organization are keeping few thousands of items in inventory. It is not

possible to have very strict control and supervision on stock level, order
quantity and price of all the items. Even it is not possible to do inventory
control of all items it is not advisable economically that one shoud bother
about small blue items and apply very systematic and very frequent inventory
controls. It is therefore necessary to have some classification of inventory:
1. ABC analysis
2. FSN analysis
3. VED analysis
ABC ANALYSIS
In the ABC analysis inventories are divided into three different categories
according to their consumption value of various items.
CATEGORIY

% OF TOTAL VALUE

%OFTOTAL
QUANTITY

70

10

25

35
70

55

71

Item according to different category:

ACLASS

B-CLASS

C-CLASS

Acrylic Dyes

FeSO4

Micro Metallic Trolley

Hydro

Stain Remover

Setting Handle

Caustic

Lime(Soda ash)

FSN ANALYSIS:
F: means fast moving items
S: means slow moving items
N: means non-moving items

FAST

SLOW

NON-MOVING

Citric Acid

Dis. Blue 2RX

No item is there
which
is
nonmoving

Acetic Acid

Dis. Blue D2R

Golden Yellow
GG

Brasso Solution

Navy Blue 3G

Pure NID

Blue SR, Red

F3 BS

VED ANALYSIS:
V: Vital items
E: Essential items
D: desirable items

VITAL

ESSENTIAL

DESIRABLE
72

Bearing

Oil

Sponge

Electronic
parts

Lubricants

conveyer

QUALITY CONTROL
We understand that consistently delivering quality products is the only way to
earn the trust and respect of the global community. At Joy, commitment
towards quality is ever present right from the development to the procurement
of raw materials to the dyeing and finishing of the fabric.

The raw materials produced are always of the highest quality and from reputed
vendors. These are meticulously inspected for any flaws by our quality
managers. The Quality Control Team is omnipresent at every stage of the
production to ensure that the goods manufactured are of the highest possible
quality standards as demanded by the international customers.

Our extra push on the Quality Control enables us to produce world class
suiting and sheeting fabrics. We are especially renowned for the whiteness of
our fabrics.

OBJECTIVES OF QUALITY CONTROL

1. The production process will suffer due to the poor quality of raw material.
2. If the supplier does not maintain the standards parameters the consumption of
items will increase.
3. Goodwill of the company will suffer.

73

FINANCIAL MANAGEMENT

Financial management is a wide term encompassing aspects of management of

funds. The physical operations of a firm are reflected to the financial inflows &
outflows. The matching of these flows and use of fund for inputs and for
financing outputs and matching output parts are of the financial management.
The efficiency of management of funds is reflected in the minimization of cost
and maximization of profits. The overall objective of any firm is maximization of
profits, which is between income and expenditure.

Thus, financial management refers to the management of these finance

function, namely,
1. Investment decision: Funds for long term investment in gross block.
2. Financing decision: Funds for financing capital budget and current, budget
long term & short-term requirements of funds and the financing of them.
3. Dividend decision or profit allocation among various claimants, namely,
depreciation, taxation, reserves and dividend to investors etc.

74

In order to maintain a sound financial position of the firm, each and every
company must maintain a sound working capital system and must also follow a
budgetary policy, but the company must have sufficient funds for it earlier, else
it wont be in a position to work out the customers need/requirements.

FINANCE AND ACCOUNTING

MANAGER

COLLECTION
OFFICER

ACCOUNTANTS

LEGAL ADVISOR

TAX CONSULTANTS

BUGDETING
As the expenditure is of large amount and it is planed in advance, the plan is
known as capital budget. The process of taking decision of which asset is to
be purchased and how to spent funds for this purpose is called capital
budgeting.

Capital budgeting decision may be defined the firm decision to invest its
current funds efficiently in the long run activities and in anticipation of an
expected flow of future benefits over series of year.

75

Capital budgeting is concerned with allocation of the form scarce financial

resources among the devisable market the consideration of investment
opportunities involves the comparison of the expected future steams o earnings
from a project with the immediate and subsequent expenses for it.

In JOY POLYFAB budgeting is done on the basis of expenses of government

department, they also considered the salary and wages of the employees. They
also considered payment of color chemicals; they also make arrangement of
capital for purchasing some new machines and spare parts. So the do
budgeting in a very careful manner, so the all these payments will pay easily
and smoothly.

In this whenever the new machinery is installed, so at that time the process of
budgeting prepares all the future plans. There are many parts where huge
investment is to be done and many times happen that profit is done, so all the
investment is to be calculated because if any changes has to made then it can
be done easily., every time budgeting works under the future estimation and
condition prevailing that time.

76

WORKING CAPITAL MANAGEMENT

Working capital as a concept means the total of gross current assets of a firm,
employed in its operations. This is a going concern concept, as the
management of these assets is necessary for day-to-day operations. As per
another school of thought, net working capital is more relevant and it means
the excess of current assets over current liabilities. The working capital
management thus involves the management of both current assets and current
liabilities.

The goal of finance manager is optimization of value of the firm, which can be
achieved by maximization of profits and minimization of costs. Maintaining the
optimal level of working capital funds is necessary for this objective. The
finance manager has to keep various alternative contingency plans for meeting
the deficiency in the requirements and line up alternative avenues of using the
excess funds, if there is a surplus. This particular temporary component is
thus crux of working capital management.

PERTICULER

2007

2008

2009

CURRENT
ASSETS

33,549,740

32,949,546

35,986,495

CURRENT
LIABILITES

28,446,319

24,852,465

27,075,007

WORKING
CAPITAL

5,103,421

8,097,081

8911458

77

78

ACCOUNTING POLICIES FOLLOWD

Accounting policies are various accounting basic rules that are followed by an
organization/company. Each selects certain set of rules that it finds suitable
for itself and follows them. During auditing of the accounts, the company to the
auditor specifies these rules and hence they are noted at the end of the audited
report.
The policy Followed by JOY are:
1. Accounting Convention: The financial statement is prepared under the
historical cost convention in accordance with generally accepted accounting
practices. All items of material nature as regards financial statements have
been accounted ongoing concern less and accrual basis.
2. Fixed assets: Fixed assets have been started at cost plus all expenses directly
related to bring the assets into working condition less depreciation on DBM.
3. Inventories: Inventories have been value at cost.
4. Previous year figures are rearranged whenever to make them comparable with
the current years figure.

79

80

INVENTORY VALUEATION & CONTROLING

The subject to inventory control is an integral part of production planning. The

area of inventory control is one in which the firm must decide what levels of
inventory can be economically maintained. These inventories consist of raw
material and component parts, which the company procures from external
sources and component part and finished assemblies, which the company
manufactures itself. For a given item, there will be some level of inventory,
which will yield a total cost which will be lower than the total cost generated, by
any other level. What the firm must do is determine what this most economical
level is for each purchased and manufactured item and then maintain the
inventory at this level.

CALCULATION OF DEPRECIATION

At some point of time, assets become useless and are disposed off and possibly
replaced. The economic potential so consumed represents the expired cost of
these assets and must be recovered from the revenue of the business in order
to determine the income earned by the business. Depreciation may, therefore,
be defined as that portion of the cost of the asset that is deducted from revenue
for assets services used in the operation of a business.

Thus, from the above definition, it can be concluded that depreciation is a

gradual decrease in the value of asset from any cause like;

Wear & tear

Exhaustion
Obsolescence
Accident, etc.

There are various methods on basis of which depreciation can be provided in

any organization. Some of them are:
1.
2.
3.
4.

Uniform charge methods.

Declining charge or accelerated depreciation methods.
Group depreciation method.
Inventory system of depreciation.
81

5. Annuity method.
6. Depreciation fund method.
7. Insurance policy method, etc.

82

The one followed at JOY POLYFAB is diminishing balance method (DBM).

Under this method, depreciation is written off at a fixed percentage rate every
year. The depreciation keep on reading every year as the balance or the fixed
asset keeps on reading simultaneously. In such a method the positive feedback
received is that the value of fixed asset never reaches zero, hence, a scrap value
of the asset can be ascertained at the end of its life.

COMMON SIZED STATEMENTS

Common size financial statements are those in which figures reported are
converted into percentage to some common base. In profit and loss account,
sales figure is assumed to be equal to 100 and all other figures are expressed
as percentage of sales. Similarly in balance sheet the total of assets or liabilities
is taken to be equal to 100 and all the figures are expressed as percentage of
the total. The statements so prepared are called common size statement.

TREND ANALYSIS

In simple words, trend means any general tendency. Analysis of these general
tendencies is called trend analysis. In interpretation of financial statements,
trends analysis has major importance. The main purpose of trend analysis is to
know the trend of available financial data. With the help of this analysis,
forecasting of future trend can be done easily.

83

84

PRESONNEL MANAGEMENT
Personnel management is the planning, organization, directing, and
controlling of the procurement, development, compensation, maintenance, &
separation of human resources to the end that individual. Organizational and
societal objectives are accomplished.

Personnel management is one of our most complex and challenging field of

endeavor. Not only must the requirement for an effective work force be met, the
personnel manager must be greatly concern with the expectation of both
employees and society in journal.

The purpose of the entire activity outline above, both managerial and operative
is to assist in the accomplishment of basic objectives. Consequently, the
starting point of personnel management, as of all management, must be a
specification of the objectives and the determination of the sub-objectives of
the personnel function.

Personnel Management at JOY POLYFAB

A company can be no better the people who it. JOY POLYFAB has learn to
acknowledge that in the progress of its people, line the progress of the
company. Good as individual, better as a term, these people are essentially the
strength of JOY.

The management at JOY POLYFAB also encourages participative management.

Where every individuals ideas put together counts in total development of the
company.

To achieve the highest level of self-motivation among its employees, JOY

POLYFAB leaves no stone unturned in ensuring that it goes a step beyond to
assure excellent living and working condition. Congenial housing facilities, best
of investigation and curative medical facilities, subsidized food and clothing,
sports and entertainment facilities for the employees and their family, regular
get together, are some of the basic steps towards the employee welfare.

85

86

MANAGING DIRECTOR

Production

Marketing

Customer
Relationiio

Collection
& Payment

n
Production
manager

Maintenance

Purchase

Store
Keepin

Color & Chemical

Purchase

g
Assi.Manager

Finance

Purchase

Store
Keepin
g

Assi.Manager

Insurance

Time
Keeping
Account

Banking

87

88

HUMAN RESOURCES PLANNING

Human resources planning may be defined as, the process of forecasting the
future manpower requirement, analyzing the present manpower resources to
determine their adequacy both quantitatively and qualitatively and planning,
the necessary programs of recruitment, selection, training, development,
motivation and compensation to meet the future manpower requirements.

MAJOR ACTIVITIES OF H.R. PLNNING

The major activities involved in manpower planning of the company include the
following:
1. FORECASTING:
The management forecasting in manpower requirement on the basis of specific
future plans.
2. INVENTORYING:
The management prepares a comprehensive account to present manpower
resources.
3. ANALYZING:
The management analyses the degree to which the present manpower
resources are utilized optimally.
4. ANTICIPATING:
The management anticipates the manpower problems by projecting present
resources into the future.
5. PLANNING:
The management prepares the necessary programmed of recruitment,
selection, training, development, motivation and compensation to meet the
future manpower requirements.

89

In JOY POLYFAB the human resources planning is gives due importance. There
are various role performed by the manager:As staff advisor: The personnel manager of the company performs the of the
staff official and specialist advisor by assisting and advising line managers on
all personnel matters.
As counselor: The personnel manager of the company act as the counselor by
attending the mental, physical and career problems of employees and giving
them appropriate advice.
As mediator: He acts as a mediator between labor and management, one
individual and another individual, to settle disputes between them.
As conscience role: He also reminds the management of its moral and ethical
obligation towards employees.
As problem solver: He acts as a problem solver in respect of issues involving
human resource management and overall long range organizational planning.
As change agent: He acts as a change agent with respect to the introduction of
major institutional changes.

Factor influencing the preparation of forecast human resource

requirements

The factors, which influence the preparation of forecast of human resource

requirement of the company, include the following:

Future plans of expansion of operations, services, and facilities.

Changes in organizational structure (e.g. likely extent of decentralization,
creation of new staff unit)
90

Change in technology to be adopted for production activities e.g. extent to

mechanization and automation.
Likely turnover to present manpower.
Likely retirement and termination of services.
Likely promotion and transfers of its present personnel.

RECRUITMENT, SELECTION & INDUCTION

Once the determination of human resource requirement has been made, the
recruitment and hiring processes being. Recruitment is a process of searching
for prospective employees and stimulating them to apply for jobs in the
organization. It is often termed positive in that its objectives are to increase
the selection ratio, that is, the number of applicants per job opening. Selection
is negative process because its eliminating the applicants, leaving only the best
to be placed in the firm.

RECRUITMENT

Recruitment is the means by which an organization establishes contact with

potential candidates, provides necessary information and encourages them to
apply for job. A company can adopt many ways to recruit employees in their
organization. There are two sources of recruitment external and internal.

JOY POLYFAB uses external sources for recruitment. External sources of

recruitment includes:

Contractors
Past applicants
Employees recommendation
91

Through above mention sources the company gets application. After that Mr.
Ramesh patel with respective HOD weed out the unsuitable candidates.

INDUCTION

Induction is concerned with problem of introducing or orientating a new

employee to the organization. The staff personnel unit usually conducts the
induction. Subjects covered include products of the company, employee
benefits, salary schedules, safety, probationary period, time recording and
absences, equal employment opportunity programs, and the grievance
procedure.

In JOY POLYFB, as there is no special personnel department, induction is

provided to the new worker HOD as he is the one who handles the personnel
functioning. He provides thorough information to the worker about his coworkers, his job positioning, his salary, his safety equipments, etc.

JOB DESCRIPTION & SPECIFICATION

A detailed knowledge of the nature and requirements of jobs to be field is

essential for determining the kind or quality of personnel required. Such
knowledge can be obtained through the process of job analysis.

Job analysis has been defined as the process of determining by observation

and study the tasks, which comprise the job, the methods & equipments, used,
and the skills and attitudes required for successful performance of the job.

JOB DESCRIPTION

92

It is a factual and organized statement describing the job in terms of its title,
location, duties, and responsibilities, working conditions, hazards and
relationship with other jobs. It tells us what is to be done, how it is to be done
and why. The main object of a job description is to differentiate it from other
jobs and to set out its outer limits.

JOY POLYFAB though being a Small Scale Industry,understands its

importance, hence it provides a job description to its worker but on an informal
basis, i.e. in verbal from as the job positions in it are not very complex in
nature. The employee, right at the time of the induction itself is made aware of
the duties he has to perform, what are his rights, what is his job, how should
he work, where he should go where not, etc.
DYEING TECHNICIAN
Dyeing is a highly technical process, due in part to the wide range of different
fabrics now used in the textile industry.

Technical dyeing technicians work out the chemical recipes for dyes and decide
on the correct treatment for different sorts of fabrics. The fabric may need a
special finish such as waterproofing and the technician will need to work out if
it will affect the dyeing process. They carry out tests to ensure that the color
matches exactly, that the fabric takes the dye, is colorfast and will not fade or
run when washed.

Technicians adjust the make-up of the and change the machine setting if
necessary. They supervisor the dyeing process, keeping on the operatives and
the machines. They keep detailed records of dye recipes and processes so that
problems can be traced necessary.

Technicians need good knowledge of other finishing processes, such as

bleaching and printing. They work with suppliers, other technicians,
technologists and sometime designers.

WORKER

To operate different machines.

To inform plan manager about production out put quality when batch is
finished.
93

To pack the material in plastic bags and load them on tempos.

HOURS AND ENVIRONMENT

Hours of work vary between 40 to 48 hours a week. Some companies operate a
shift system, and overtime is often available.

JOY dyeing house is light and spacious with good ventilation but the
atmosphere may still be humid. When in the dyeing area, they wear protective
clothing including overalls and safety footwear, and possibly headgear and a
mask.

Technicians also work in laboratories carrying out tests, and at a desk writing
reports or recording details on computer. A great deal of their time is spent
standing, supervising both machinery and operatives, or walking around the
processing area.

JOB SPECIFICATION

Job specification or man specification or employee specification is a statement

of the minimum acceptable human qualities required for the proper
performance on a job. It is a written record of the physical, mental, social,
psychological and behavioral characteristics, which a person should possess in
order to perform the job effectively.
All these trains may be classified into three categories:
1.Essential attributes, which a person must possess.
2.Desirable attributes which a person ought to possess.
3.Contra-indicators, which will become a handicap to successful job
performance.

94

DYEING TECHNICIAN

A high level of scientific and technical knowledge

Good practical skill
A logical analytical approach
Problem-solving skill
The ability to work under pressure
A keen eye detail
An organized and methodical approach to working
Good communication skill both written and verbal
The ability to get on with a wide range of people

WORKER

Should have knowledge about the working of various equipments and

working on them.
Should be free any type of allergy from chemical or any sort of prior
diseases

95

96

PERFORMANCE APRRAISAL

According to flippo, performance appraisal is the systematic, periodic and an

impartial rating of an employees excellence in matters pertaining to his present
job and his potential for a better job. It is the process of obtaining, analyzing
and recording information about the relative worth of an employee.

Hence, in order to maintain the high quality of the worker, he needs to be

appraised from time to time in order for the company to keep achieving its
goals. The main objective for which performance appraisal is carried out in JOY
POLYFAB is:
1. To provide feedback to employees so that they come to know where they
stand and can improve their job performance.
2. To provide a valid database for personnel decisions concerning
placement, pay, punishment, etc.
3. To diagnose the strengths and weaknesses of individuals so as to identify
future training needs.
4. To provide coaching, counseling, career planning and motivation to
subordinates.
5. To test the effectiveness of recruitment, selection, placement and
induction programmers, etc.

All employees are appraisal on their job performance in some manner or

another. In genera, it can be said that the choice lies among three possible
approaches:
1.A casual, unsystematic, and often haphazard appraisal.
2.The traditional and highly systematic measurement of (a)
characteristics, (b) employee contributions, or (c) both.
3.Mutual goal setting through a management by objectives program
(MBO)

JOY POLYFAB majorly follows a casual appraisal method. The company doesnt
follows any systematic means for performance appraisal but on basis of the
worker performance JOY POLYFAB appraisal it worker & staff. HOD or
immediate supervisor solves the problem directly.
97

98

EMPLOYEE WELFARE

Rapid industrialization and urbanization have made employees department on

capitalists. Inflation has made their lot poor and they find it difficult to
maintain their standard of life. In such situation, employee welfare facilities
enable worker to live a richer and more satisfactory life.

According to I.L.O. report, porkers welfare may be understood as including

such services facilities and amenities, which may be established in, or in the
vicinity of undertakings, to perform their work in healthy and congenial
surroundings and to avail of facilities, which improve their health and bring
high morale.

The various welfare services that is done by JOY POLYFAB can be divided into
two broad categories, namely: (a) Intra mutual and (b) Extra mutual. Some the
intra mutual and extra mutual services provided by the organization are:

Intra mural welfare activity of Joy

Convenience and comfort during the work

Workshop and cleanliness, lighting, elimination of dust, smoke, gases
Supply of necessary beverage, pills and tables, tea, coffee
Distribution of work hours and provision for rest hours, meal times and
breaks
Medical facilities
Compensation for accidents
Safety instruments such as guards, caps, shoes, aid equipments
Uniform and changing rooms
Urinals and latrines, wash basins, waste disposal
Provision for drinking water
Economic services such as health insurance and bonus schemes

Extra mural welfare activity of Joy

Transportation
Communication facility
Security
99

Training and development programs

100

Welfare activity for society

Provide employment
Effective waste disposal system
Effective use of resources of society
To provide an evidence of what has taken place in the organization.
To supply information required for taking personnel decisions.
To provide a basis for the formulation, evaluation and modification of
personnel and program.
To meet statutory obligations under various labor laws.

101

TRAINING AND DEVELOPMENT

Training is a learning process which seeks a relatively permanent change in

behavior that occurs as a result of experience. Training refers only to
instruction in technical and organized operations. Training courses are
typically designed for a short term, stated set purpose.

In Joy training is given with the objective of increase in productivity of

employees, increase quality of work, enhance and update knowledge and skills
of employees and many others but there is no without training program in Joy.
Joy provides training as on job training and give training to new employee. In
pharmacy, training is given to the workers which are basically at period of one
month.

On job training is training is training in which pharmacy and its members are
help and provide guidance, if there is any difficulty in any work.
Development is the process of transition of an employee from a lower level of
ability, skills and knowledge to that of higher level. Pharmacy also run program
of development periodically. Pharmacy tries to develop new skills, techniques
and personality of their employees.

TRAINING
Training is the process of increasing the knowledge and skill for doing a
particular job. It is an organized procedure by which people learn knowledge
and skill for a define purpose. The purpose of training is basically to bridge the
gap between job requirements and present competence of an employee.
Training is aimed at improving the behavior and performance of a person. It is
102

a never ending or continuous process. Though training is closely related with

development. Yet it needs to differentiate from this term.

Individual skills are synchronized with the corporate objectives and this makes
it possible for common people to attain uncommon results. Extensive training,
workshops, seminars are organized for administrative staff & workers by JOY
POLYFAB.
on the job training is give for production site which include:
For Boiler: 6 month training is given for boiler.

MOTIVATIONAL POLICY
Cubin has defined motivation as follows: motivation is the complex forces
starting and keeping a person at work in an organization. Motivation is
something that moves the person to action, and continues him in the course of
action already initiated.

According McFarland, motivation refers to the way in which urges, drives,

desires, aspirations, strivings, or needs direct, control or explain the behavior
of human beings.

The company in order to maintain the worker in the organization follows

various policies and provides various incentives and other appraisal benefits
also. To achieve the highest level of self-motivation among its employees, JOY
leaves no stone unturned in ensuring that it goes a step beyond to assure
working conditions. Best of investigation and curative medical facilities,
subsidized food and clothing, education, sports and entertainment facilities for
employees and their family, regular get together, are some of the basic steps
towards the employee welfare.
103

104

WAGE & SALARY ADMINISTRATION

Employee compensation is a vital part of human resources management.
Wages, salaries and other forms of employee compensation constitute a very
large component of operating costs. One of the biggest factors affecting
industrial relation is the salary or wage the compensation an employee receives
for a fair days work.

No organization can expect to attract and retain qualified and motivated

employees unless it pays them fair compensation. Employee compensation
therefore influences vitally the growth and profitability of the company. For
employees, pay is more than a means of satisfying their physical needs. It
provides them a sense of recognition and determines their social status.
Recruitment is directly or indirectly one of the mainsprings of motivation in our
society.
In JOY, the wage payment system followed is Time wage system. Under this
system, wages are paid on the basis of time spent on the job irrespective of the
amount of work done. The unit of time may be a day, a week, a fortnight or a
month (generally month). But at JOY salary & wages are given on monthly
basis.

105

FINDING AND RECOMANDATION

FINDING

During my Project report at JOY, I have found that company going to fastest
growing export of fabrics with the strong global presence.

JOY has also efforts to provide the customer with the best possible quality at
the most competitive rates with a constant emphasis on innovation and
reliability.

I also find that the every stage of production to ensure that the goods
manufactured are of the highest possible quality standards as demanded by
the international customer.

In a company gives the best services to the workers so they are doing a work
better and maintain the co-ordination between workers and manager.

All the workers of the company doing work in a team work so the production
going fast.

I also find that the company or process going through systematically and stepby-steps so they are increase their capacity to produce per day production.

RECOMMENDATION

The company should increase their share out.

106

Company is also providing the welfare facility to extramural facility to employee.

Company having one branch in vapi so they have to establish a new branch for
increasing their export business.

They also focus on that barriers which are affect to their expanded business.
(competitors, market demand and other factor.)

I suggest that the company are looking ahead to that the world business
scenario is now changing at a very fast pace with development of technology.

CONCLUSION

During the entire duration of training programmed, I learnt the success of ant
task lies in the root of the effective input. The task can never be accomplished
without team work and co-operation from others.

I also learnt gained some intellectual knowledge regarding the qualities that a
management should have in order to fulfill the companys requirements.

The effective and good management of the company has a very much
performance status and the overall performance of the company is rapidly
emerging as one of the fastest growing exporters of fabrics with a strong global
presence.

In overall period of training I got the good opportunity to study a well known
and reputed company like JOY which helped us in understanding how things
work in real life and what practical implication of our knowledge can be done.

107