Record Colony Group is one of the leading and earliest Textile Production group in Pakistan. The 1st industrial venture of the group is at cotton ginning sector last 1881. Gradually the group diversified into flour milling in the early 1900s. Initially textile rotating plant was put up in 1946 under the name of Nest Textile Mills Limited. The Group even more ventured in to Banking, Insurance, Cement, and Power Technology & Distribution. By 1952 Colony Textile Mills Limited was a composite resin textile herb with a 120, 000 spindles, 1, five-hundred looms, and fabric finishing capacity around 150, 000 meters daily.
Nationalization of 1972 took almost all of the business aside, leaving Linen and Insurance in the Group. Presently, there are two businesses in the group, namely, Colony Textile Generators Limited (CTM) with regarding 195, 500 Spindles, and Colony Companies (Pvt. ) Limited (CIL), consisting of thirty-five, 000 Spindles and 418 Air Jet Looms. Thickness | Looms| | 190cm| 180| 176 Cam +12 Dobby & 12 Crank (20 Harnesses with Batchers)| 210cm| 24| 24 Camshaft Looms (4 Looms with Batchers)| 280cm| 26| 20 Cam & 6 Dobby| 340cm| 188| 174 Cam + 14 Dobby| Competitive Dimensions CIL is a very good and only group that has 418 Looms in same place.
This helps in fulfilment of enormous orders for high speed. In case the looms during installation at distinct locations large orders cannot be processed as a result of factors just like communication buffer and increased cost of transportation etc . An additional unique factor CIL has is the Automated Drawing in machine. Once order of new quality is usually received it needs to be made for the weaving loom to focus on. If manually this process is carried out the time instructed to feed the modern design inside the loom will be around of sixteen hours. Time CIL usually takes to do similar task is just 2 hours with better productivity.
This automatic machine is only available at CIL and increases order fulfilment speed. The power requirement for the setup of 418 looms, compressor fleets and other support functions is 8MW. The cost of power i actually. e. electricity is lowered to a greater extent by manufacturing through its own power generation program which generates 10MW through Natural gas. In addition for an uninterrupted supply of electrical power CIL has its grid stop. Similarly CIL’s own compressors fleet decreases the cost of raw material we. e. pressurized air which will prevents the machinery via heating up and keep humidity and temperatures.
Capability Capacity or the production of looms considerably depends upon the quality of fabric. In the event fabric features high quality production will be significantly less. The reason behind this can be high quality cloth uses good threads. Production also is dependent upon the number of strings used in manufacturing. 6 million meters each month approx creation has been registered by CIL. Initially there are 120 looms at CIL. Capacity addition was required for March june 2006 and 154 looms were added. Capacity addition for the 2nd time was done at the end of third quarter with the help of 144 harnesses making development capacity of 6. zero million meters fabric monthly.
Core Providers and Value Added Services The core support of CIL is grey fabric developing. They may provide inside information of accounts, functions etc . to external people. However they present samples to their clients that are sales support. Field support is also difficult in this weaving business nevertheless they do correct the mistake within the particular time. Are unsuccessful Safing methods Automated action sensors Automatic motion detectors stop the process of creeling, sizing and weaving whenever a carefully thread breaks down or any error shows up in the process. This prevents errors from increasing. Online Inspection System
Online Inspection strategy is a manual system with which errors may be checked by simply mills administrator. The data is fed to the system by operators and it is evaluated simply by mills manager for removal of errors. During Production Bank checks Technicians and operators are responsible for checking out and taking away the errors during production. After Development Checks Inspection and foldable department rectifies error whether it still exists before providing. After taking the purchase is randomly checked so that client gets error free of charge order. Process Selection The kind of processes they may be using at most basic level is usually Fabrication rocess that means Colony Industry turns their natural material we. e. organic yarn to grey textile. Grey textile is the type of fabric just before printing or perhaps dying. This procedure of manufacture is known as Weaving in the terminology of Textile organization. Yarn movement is structured in the manufacturer by method technology generally known as batch shop. Yarn is retrieved via yarn purchase department since the purchase is received for the availability of greyish fabric after which it is processed in the form of amounts or buy. Mill involves 3 Devices each having 2 Outdoor sheds which are control units. Hierarchy of expert is in Appendix.
Each Product is went by Mills manger etc. Production in charge are responsible for 60, senior technicians for 16 and Operators for 4-6 harnesses. Warping Creeling Quality Verify Yarn High Spinning Work Low Sizing Head Stock Warper Beams Drawing In Sizing Roll Inspection Bo?tes Packaging Weaving cloth Approve Pallets Disapprove Storage Treatable Handle Yes Not any Waste Simply no Flow Data Marketing section receives purchase and copy production in an attempt to the mill. Mill personnel plans the order and tells wool procurement division for wool purchase. This kind of department buys yarn from colony’s rotating mill and also other spinning mills.
The wool is not stored in the mill nonetheless it is received from the supply when needed. Once yarn can be received by the mill it really is sent to top quality check department for inspection where wool is considered and tested for locks and tension. If the wool is certainly not approved, it is sent back to the source in any other case it is used in the next office. This yarn is in the form of spindles which can be loaded about creeling equipment manually. Then the process of warping starts by which these spindles are unrolled and folded on the bending beams which can be then transmitted for dimensions.
In the process of sizing, starch and polyvinyl along with some other chemical compounds and drinking water are grilled and placed on the wool. This process makes yarn capable to go through the subsequent steps simply by increasing its strength and elasticity. After drying the yarn, ends are separated in a manner that they cannot stick to the other person. This dried up yarn is usually rolled on temporary safe-keeping which has the scale according to the size of the material known as dimension head stock. After the technique of drawing in as discussed previously, it truly is injected to the loom pertaining to the process of weaving cloth. The temp is managed by a special system of converter fleet.
When weaving is completed, inspection of each inch of cloth is done pertaining to quality assurance in which decision is manufactured regarding acknowledgement, rejection and mending of cloth. After acceptance, it is directed for packaging as mentioned in production order and if textile is not really approved, it really is mended normally it is sent to the spend. Back Method: In Warping, the whole system is of Ben-Direct Benninger Versus 1080/2400. Nest Ind. offers 6 Warping machines while using Creel Capacity of 1080 each. Each machine is with the digital sensors intended for the doing a trace for of damaged ends. In Sizing, Colony has the Ben-Sizetech Zell KVE, Creel thirty-two WW/4000 machines.
Colony offers 4 Dimension machines, a few with the Brain Stock scale 4 metres. Total Creel Capacity ranges from 16 (1 m/c) to 28 (1 m/c) right up until 32 (2 m/c’s). The Sizing equipment is with pre-wet technology with double dip sow-box. Colony has an further facility of Beam Stacker which is not located anywhere else in Pakistan. Colony is equipped with 2 Beam Stacker from Formia Nova of Italy with total of 65 pubs holding the capability of 195 no of beams for Narrow & 130 not any of beams for Wider. DRAWING-IN Nest has the state-of-the-art 2 Computerized Drawing-In equipment which is discovered rare in Pakistan.
One particular machine is from Staubli (Delta 110-4) which has the capacity of a hundred and fifty, 000 ends/day filling together with the speed of 140 threads/min. The 2nd machine is by EL&M S i9000. P. A (Super Vega) which has the 80 threads/min filling speed. Weaving Colony has the total production of 6. 00 million yards fabric/month with 418 harnesses all of Toyota JAT 710 in development. In the one hundred ninety cm section (Narrow looms), they have one hundred and eighty looms, twenty-four with the batching motions.
Folding machines has the total capacity of 25k/shift/machine. Rolling machine is to use the production of 10000 meters fabric/shift/machine Top quality Inspection/folding is the process for quality investigations. In this method each ” of fabric is definitely inspected. The quality of fabric depends on the acumen of customer and is examined according to the productivity of loom stated in Development Order. Selling price also improves with the fineness of the cloth. During the process in the event any defect is found than it is decided according to the characteristics of the defect whether to permit it or treat the material. Then fabric is classified into 3 grades A, B and C.
A is best category which is considered to be of export top quality, while N and C are of lower top quality. They adhere to 4 level system which allows maximum of four errors and is world wide approved. Colony provides fully outfitted Quality Research laboratory with all sort of testing tools including the Uster Tester four for wool checking. Quality Lab make certain that there is no bargain in the quality of the wool used & the fabric produced. The whole system has the examine points coming from Quality Section from Backside Process to Article, via Inspection to packing, thus resulting in the production of 1st class A-Grade fabric because committed.
Colony has the Gift wrapping Reel by Mesdan Italy with the Model # S-389 A used intended for the producing of lea. It comes after the ASTM standard of D-1907-01. Car Sorter is usually from Uster Switzerland with all the Model PUBLIC RELATIONS 503 DOCTOR Most Important equipment in the Laboratory of colony is Uster UT -4 with the Version SE 400101-02100. Make of UT-4 is by Uster Switzerland for the checking of IPI’s in the yarn. To get the examining of Hairiness in the wool, colony has got the Hairiness Specialist from Zweigle Germany with all the Model G-567. To check the Tear Strength of the textile, colony provides the Tear Strength Tester from Zweigle Indonesia with the version FX-3750.
Their particular primary emphasis is top quality because CIL is export based organization. If top quality is certainly not up to the mark clients move to Bangladesh and Chinese suppliers because they give cheap items with cheap. Pakistani fabric is famous for it is high quality and perfection. Tips: 1 . Product sales of community sector will be dependent on few companies. The proportion of sales should be changed so that colony’s risk is minimized. This will likewise help in increasing performance since it will result in deal increase. installment payments on your Sale every order should be considered and aim should be “the more worth of purchase, higher needs to be the frequency of order. 3. Monitoring systems that allows on-line communication and control of harnesses should be mounted to manage the system more accurately. some. Employees ought to be decreased simply by bringing in automated creeling machine which decreases the time by simply automatically getting rid of the spindles once the line is removed from them. your five. Operations focus should be on wide looms as they have said that these wide looms have got generated higher inflows. 6. Capacity addition should be held in view as it has been around three years now before the very last addition was performed. 7.
Training of personnel by mailing them to technological institutes abroad should be done while fail safing technique to reduce the chance of defect in the fabric. 8. Nest has fewer inflows in exports and greater in local as a result sales initiatives should be involved to increase regional orders and increase inflows from export products. 9. Nest should use ingredient branding like they can market all their cloth by informing customers about the brand name of Looms Company possess installed. 10. Operations coverage should be manufactured and analyzed continuously. Every employee must be involved in building the plan. Appendix