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ABOUT COMPANY

Alok Industries Ltd is one of the Indias largest Vertically Integrated Company. It
is headquartered in Mumbai with its manufacturing units in Vapi, Silvassa &Navi
Mumbai. The company is an end to end provider of integrated textile solutions
with five core divisions: - Cotton yarn, Polyester yarns, Apparel fabrics, Home
textiles, and Garment.

History
Alok was established in 12 th March 1986 as a private limited company with first
polyester texturizing plant being set up in 1989.
The name of the company was changed to Alok Textiles Industries Private
Limited on 17th November 1992 and converted into Public Limited Company on
11th February 1993.
In the year of 1996 Alok industries started knitting division in silvassa. Alok
industries have expanded into weaving, processing, home textiles and garments.
Alok industries have integrated backward into cotton spinning and manufacturing
partially oriented yarn through the continuous polymerization route. Alok
industries also provide embroidered products through Grabal Alok Impex Ltd.,
our associate company.
In the year of 2007 Alok Industries entered into the domestic retailing business
under the name Homes & Apparel that is H & A.
In the year 2008 Aok Industries as IMS that is Integrated Management System.
Alok Industries then further stepped for continuous polymerization in the year
2009 and in 2011 polyester staple fibre.
Alok Industries has an international presence in retail segment through its
associate concern, Grabal Alok (UK) Limited.

Alok is an end-to end textile solutions provider. Its products encompasses the
entire value chain from cotton and blended yarn to fabric to garments and home
textiles. A significant portion of these product are cotton based- manufactured
from both organic cotton and regular cotton; blended and polyester yarn offerings
also form part of Alok portfolio of products.

ALOK INDUSTRIES COMPANY PROFILE:

Founder Chairman: Bhagirathaml Jiwarajka.


Chairman: Ashok B.Jiwarajka.
Managing Director: Dilip B. Jiwaraka
General Managing Director: Surender B. Jiwarka.

ALOK INDUSTRIES TEXTILE PLANTS

MUMBAI HEAD OFFICE , GARMENT DIVISION

SILVASSA

VAPI

DAMAN

SPINNING,
WEAVING

DYEING &
PRINTING

GARMENTS

TEXTURISING

Alok industries competitors:

Arvind mills
Reliance
Bombay dyeing
Creative garments

Certification to Alok industries:

ISO 9001 : 2008 (Quality Management System)


ISO 14001 : 2004 (Environmental Management System)
OHSAS 18001 : 2007 (Occupational Health and Safety Management

System)
SA 8000 : 2008 (Social Accountability / Social compliance )

Aloks vision :-

To be the worlds best integrated textile solutions enterprise with leadership


position across products and markets, exceeding customer & stakeholder
expectation.

Aloks mission :

Be a knowledge leader and an innovator in our business.


Maximize people development initiatives.
Optimize use of all resources.
Become a process driven organization
Exceed compliances and global quality standards
Actively explore potential markets & products
Offer innovative, customized and value added services to our customers
Be an ethical transparent and responsible global organization.

VALUES OF THE ORGANIZATION


Customer Satisfaction
Alok will be attuned to market needs; wherever possible, It anticipates market needs;
respond quickly to changes in customer requirements.

It

It completely focused on quality. It

keeps delivery commitments on time and every time. It develops new products and processes
that go beyond customer satisfaction to achieve customer delight.

Passionate About Excellence


Excellence is non-negotiable in every aspect of their business process. Superior quality of
performance is critical to their business growth and success. They constantly strive to exceed
expectations: be it internal or external.

Developed Human Capital


They empowers, energise and inspire their people to perform beyond their best; they will create
empowered teams that take informed decisions; they recognize and leverage skills and

strengths of various teams; they enable sharing of knowledge; they creates an adequate 'bench
strength' that takes care of changes in business scenarios.

Fair To All
All their actions are determined by fairness; they are fair to their customers, vendors,
shareholders, all their business partners and society at large. Fairness is not just sticking to the
letter of the law or the contract but appreciating its spirit and basing all their actions on being fair
to the spirit of that understanding.

Concern for the Environment and the Community


They takes the utmost care of their environment and the communities in which they operate;
they nurture their environment and its natural resources and ensure that none of their actions
deplete or pollute them; they encourage initiatives that create environmental sustainability and
help in community development.

Safety and Health


They provide a safe workplace. They promote the health and well-being of their people and
their families. They encourage healthy work habits and a 'work-life' balance. They believe that
working safely and protecting the health of their people is 'working smart' and creates greater
and more sustainable wealth.

Responsible Corporate Citizen


They recognize that they have their responsibilities towards the society in which they operate.
They commit their selves to be a responsible corporate citizen; their activities should not only
create shareholder wealth, but also community wealth.

2.Fire and Safety Department


This department provides training to new workers and at the same time assuring
healthy working environment to the employee. This department works under the

standards of OHSAS18001 (Occupational health and safety management


system).
In order to promote uniform standards in health, safety and environment (HSE),
every company has developed tools for establishing, auditing and monitoring the
industry.
Fire department have their sprinklers, monitors, pump house etc. installed in the
industry to ensure that fire doesnt harm any personnel. There are two different
types of fire extinguisher used by department
Portable extinguisher (Trucks, fire extinguisher cans etc.)
Fixed extinguisher (Sprinklers, pump house etc.)
There can be different causes of fire in industry thats why fire are classified into
4 different class.
Class A:- Class A Fires consist of ordinary combustibles such as wood, paper,
trash or anything else that leaves an ash. Water works best to extinguish a Class
A fire.
Class B: Class B Fires are fueled by flammable or combustible liquids, which
include oil, gasoline, and other similar materials. Smothering effects which
deplete the oxygen supply work best to extinguish Class B fires.
Class C: Class C Fires. Energized Electrical Fires are known as Class C fires.
Always de-energize the circuit then use a non-conductive extinguishing agent.
Such as Carbon dioxide.
Class D: Class D Fires are combustible metal fires. Magnesium and Titanium
are the most common types of metal fires. Once a metal ignites do not use water
in an attempt to extinguish it. Only use a Dry Powder extinguishing agent. Dry
Types of
powder agents work by smothering and heat absorption.
f
r
e

In Alok, for immediate help, there is Manual Call Points (MCP) fitted. They are of two types.

One has push buttons that we are supposed to press if any fire occurs.
Another one is break glass". They are used to allow building occupants to signal that a
fire or other emergency exists within the building. Under normal conditions push button
will be in the depressed condition. In the case of fire when the glass cover is broken, the
push button will be released by the spring action and will actuate an alarm at the control
panel through its switching contacts. In addition to this, there will be an LED indicator on
the monitor module for visual indication to locate the call point easily.

There are also smoke sensors which detect the smoke immediately and as soon as it senses
the smoke, water is sprinkled by the device.
There are total 6 private fire vans that Alok owns. Two of them are Mercedes foam tender and
foam nurser,

Fire department uses different method for different class of fire.


Cooling:- Class A
Smoothening & covering:- Class B
Starvation method etc.

Safety department works over a guideline detailing the requirements which allow suppliers to
comply with the company Standards of Engagement (SoE). The guidelines described do not
necessarily reflect the national laws of all countries where suppliers are based, and it is
responsibility of individual suppliers to ensure that they meet all legal requirements relating to
health, safety and environmental matters.

2. RAW MATERIAL DEPARTMENT


2.1 Grey yarn store room
In this inventory grey yarns are stored that comes from either alok spinning unit or from
different spinning mill from all over india.

Process Flow of department:a.


b.
c.
d.

PPC is developed by PPC department.


Booking of Material is done by Head Office in Mumbai
Material comes by truck to the industry.
Department sends some of the sample to Quality Assurance Department for quality check
from the truck.
e. If material are not of acceptable quality then they are returned to the manufacturer.
f.

If materials are accepted quality then they are allotted a position in store room by
department.
g. Unloading is done and materials are placed on its position.
h. According to the order from weaving department raw material are dispatched from store
room to other department.

Storage capacity of store room :- 1200 ton


Average weight of a cone :- 2.5 kg
Raw material generally comes in two form in alok: Conical form
Chesse form

2.2 Dyed yarn store room


In this inventory grey yarns are stored that comes from either alok spinning unit or from
different spinning mill from all over india.
Process flow of this inventory is also same as grey yarn inventory.
Storage capacity of the store room :- 250 ton
Weight of the cone depends on the order placed.

Different Material, Type and Blends of yarn available in alok :


YARN MATERIAL
Organic Cotton
Cotton
Polyester
Viscous

BLENDED YARN
Cotton Viscous (CV)
Polyester Viscous (PV)
Polyester Cotton (PC)
Chief Value Cotton (CVC)

YARN TYPE
Carded Yarn
Combed Yarn
Compact Yarn
Core/Fancy/Lycra
High Twist Yarn
Roto/Open End Yarn

Slub Yarn

PPC (Production Planning Control Department)


PPC

is an activity that is performed before the actual production process takes place.
The main role of this department is that it communicates between markets and
production. After receiving enquiry from market the commitment of delivery date is given.
PPC also determines the cost which depends mainly on the EPI and PPI.

Objectives of Production Planning Control:

To plan production facilities in the best possible manner along with the proper systematic
planning of production activities.

Providing men, machines, materials etc. of right quality, quantity and also providing them
at the right time forms a very important factor.

To inform, about the difficulties or the various awkward positions expected to crop up
later, to the management before hand.

Working Procedure:

Desk Loom (for color matching)

Sample

Proto Sample (for garment look)

Sales Man Sample (fabric look, type of garment)

Bulk Sort creation


o

Unique identification code is given to the order with this number the order is
identified throughout the process

Costing

Inquiry (Date of Grey delivery & Finish delivery)

Sales order (Legal Agreement of Order)

STPO (Stock Transfer Purchase Order)


o

The final order detail is send to Mumbai and from there it is send to all the
departments. It includes all the wastages and shrinkage during the process.

Designing

Pattern Paper (for Loom)

Production Order (In PPC)


o

This production order is sent to all the departments like raw material,
preparatory, loom shed.

4. QUALITY ASSURANCE DEPARTMENT.


4.1 Role of department

QA department are responsible for the testing and the acceptance of raw material that comes
from different places.
o Different parameters that are checked in raw material (yarns) : Yarn strength
Yarn imperfection
Yarn count
TPI
Analyses the specimen that come from buyer.
o Parameter analyzed are : Warp count
Weft count
Types of material(In warp and weft)
Weave
Analyses working condition of worker and machine.
Audit the machines.
o Checking of machines for
Oil leakage.
Air leakage (Air jet machines).
Missing parts of machine.
Width of cutting waste
Analyses weaved fabric for defects.
o Follows 4-point inspection system.
o Defects in weaved fabric : Unevenness
Broken end
Reed marks
Broken pattern
Double peek
Loose warp etc.
In folding department QA do grading of fabric.

4.2 Test conduct in QA department

For testing of yarns first of all lot of yarns are formed.

Plan for lot formation :-

Lot size
Above 4000 kg
Above 1000 kg to 4000 kg
100 kg to 1000 kg
Less than 100 kg

No of cones
15
10
5
5

No of lot to prepare
15*1
10*1
5*2
2*5

Total no of lot formed


15
10
10
10

Designing
The objective of this department is to prepare a pattern for the weaving process to achieve the
desired effect and look on the fabric as per buyers specification. The department receives the
specifications from PPC department after sampling is done and samples are send for approval,
approved designs then go further for production. The departments perform the following work:-

Designing the product


Analysis & feasibility of product
Preparation of bill of materials required for preparing the product

Step by step process explained below.

Sample of fabric is issued from the HO as per customer requirement.

Analysis of the sample is done. Its EPI (Ends per Inch), PPI (Picks per Inch) are
calculated and type of weave is determined.

Then the report along with sample is sent to QA (Quality Assurance) for further analysis.

Specification sheet is then prepared by the Design department after getting report from
QA which has details such as warp, weft, reed, width, pick, etc. The process was
previously manual which has now been computerized.

Handloom sample along with drawing plan is then prepared which is sent to the HO
(Head Office) which then approved by customer by sales department.

After approval then it is sent to the PPC department along with order details and the
PPC department does further procedure of sizing and weaving.

Then sample of fabric is again sent to design department for approval.

Warping
The parallel winding of warp end from many winding package (cone) on to a common package
(warp beam) is called warping.
Importance of Warping:

Construction of a beam of warp yarn.

Construction of a parallel yarn sheet.

Modifying the faults of yarn like thick or thin place

Winding the pre- determined length of yarn.

Combination of small packages.

Accelerating the next process.

There are 2 types of warping used in industry:

Direct warping
The cones are placed on the creels and the ends are passed through two pre stationary
rod out of which one is stationary and is movable. These rods are responsible to give
proper tension to the yarn. There is also an auto ply tension unit with light indicator to
control tension during running and stops the machine. The yarn are passed through a
zig -zag yarn guides (dents) to the gear controlled cylindrical beam which continuously
rotates and prepares the warping beam. There is also a display at the front of operator
which indicates the breakage cone row and column number. Presser roller which is in
contact with beam ensures uniformity in formation of the warp beam an in cylindrical
from. Singles yarns are preferred for direct warping, as they are to be sized in the
successive process.
There are total 10 direct warping machines in the industry.
8 Benniger Direct warping
2 Prashant gammatex
These machines have different creel capacity:7 machines 1088 creel capacity
2 machines 680 creel capacity (machine no. 9 & 10)
1 machines 630 creel capacity (machine no. 8)
Average speed of these machines is 600 rpm

Sectional warping

Sectional warping is done in some versatile intricate and majorly yarn dyed pieces where
the consumption of different warp yarns is different depending on the design. The drum
roller intermittently winds the yarns from creels and the beam automatically moves
laterally to get a uniform wound section beam as par the data fed according to the
required design. This section warpers beam is then waxed by a winding roller in a
continuous manner which successively gets wound on the weavers beam. Double yarns
are preferable to be sectional warped. The leasing and section reeds are used to
separate different colored yarns and determine number of yarns in a dent respectively.

There are total 12 sectional warping machines.


2 Benniger
10 Prashant Gammatex
These machines have different creel capacity.
Machine no. 1&2 = 720
Machine no. 4, 5,9,10 = 960
Machine no. 12, 7, 6,11,8 = 656

Sizing
The sizing process aims at providing extra strength to the warp yarn for withstanding tension
and abrasion during weaving. Sizes used are:1. Adhesives: Modified starch (texoplast), fabric glue, thin volume starch, Potato starch,
from corn, wheat, rice, etc., Carboxyl methyl cellulose (CMC), Poly-vinyl alcohol(PVA),
Polyester resin (acts as binder).
2. Lubricants: Mineral waxes, oils, vegetable waxes and oils, animal fats.
3. Additives: Salicylic acid, zinc chloride, phenol, emulsifier, softeners, Polyethylene glycol.
Sizing machines
Sizing process
The warped beams are put on the creels an all the warp ends are passed through various
cylinders without any inter yarn entanglement and messing up of yarns.
They are passed into a bath of a water base sizing solution. The bath has a temperature of 90 0c
which has nip rollers and two dip rollers which guide the yarn for proper sizing through proper
bathing.
The yarns have continuous movement through the solution as they travel through the drying
cylinders which have temperature of 140 0c, 1300c 1250c and 1100c in the respective cylinders in
the drying chambers (zone 2 and zone 3).
Leasing region is the drying region from where the yarns get separated by dividing rods to avoid
yarn group which could create difficulties in weaving.
Thus by automatically monitored and controlled system, the yarns are wound on the weavers
beam. These weavers beams are transferred to the looms.

AUTO DRAWING IN
When drawing in done by automatic machine it called Auto drawing. For auto drawing Staubli
Delta 110 machine is used
Features of Auto drawing machine:

Manufacturer of the machine is- Staubli.

Model is- Delta 110.

Maximum speed- 140 ends/min.

Up to 20 heald frames can be applied.

Both type of drop pins i.e. open and closed type can be used.

Both type of heald wires i.e. C & J type can be used.

Selection needle is used to select a single end at a time.

Selection needle is used as per the count.

It has double end monitoring function i.e. it can detect the selection of double ends in the
machine.

In double end case, the ends are separated & the extra end is fed to an empty drop pin
& heald wire which is kept as extra for such an occurrence so that the yarn can be used
for weaving the fabric and doesnt become waste.

The drawback of this system is crossing of yarns take place, so there is a possibility of
end breakages.

Requirements for Auto drawing are:1. Program (from PPC/Weaving)


2. Beam (from Sizing/Sectional warping)
3. Heald frame & Heald wires (Weaving)
4. D-Box/ Drop pins (Weaving)
5. Reed (Weaving)

1. Program
In the program which is given by the PPC department the following details are given:
Sort No.

Beam No.

Total no. of Heald frames in body & selvedge


Draft
Reed count & denting order
Warp pattern

2. Beam
Beam is sent for auto drawing by the sizing department/ sectional warping dept.
Beam card is also sent which gives details like Warp count, total ends, sort no.
3. Heald frame/ Heald wires
Source is weaving Steps:
Removal of heald wires from heald frames.

Separation of Part 1 & part 2 heald wires

Feeding on Staubli Delta


4. D-Box/ Drop pins (warp stop motion)
The D-Box arrangement is basically used as a warp stop motion. There are serrated bars on
which there are drop pins. Each warp end is made to pass over a drop pin. Due to tension the
yarn is held tightly enough in between the slot of the drop pin. If a warp end breaks the drop pin
falls on the serrated bar & because of electrical contact the machine stops.
Usually when a yarn of count above 60 is to be woven into a fabric the heald wire used is of
0.2 mm thickness. & when the yarn count is below 60 is to be woven into a fabric the wire of
thickness 0.3 mm is used.
5. Reed
Two different type of reeds are used, Profile reed & Plain reed for Air jet and Rapier Looms
respectively

Weaving
Types of looms at Alok Industry
On the basis of weft insertion mechanism:

Air jet loom


o In the air jet loom, a jet of air is projected across the shed forcefully, that takes
the filling yarn to the other side i.e. a jet of air is used to propel the weft yarn
through the shed at speeds of up to 600 ppm.

Rapier loom
o The rapier loom is upgrade from shuttle-looms to the world of modern weaving
system and shuttle-less weaving. Rapier looms has been designed to replace the
old shuttle looms without any major changes to the existing infrastructure

On the basis of shedding mechanism:

Cam
o Cam looms have a design capability of producing simple weaves.
Dobby
o These are more complicated than Cam systems but have higher initial and
maintenance costs. Dobby looms have the capability of producing more
complicated and sophisticated weaves.
Jacquard
o Jacquard shedding mechanisms are capable of producing large and intricate
weave designs that are beyond the scope of dobby shedding mechanisms. In
jacquard weaving, it is possible to control every warp yarn individually.

There are also looms on basis of their width i.e. width of the fabric produced. One is normal
width and other is wider width machine.

Weaving Process

Sampling
Sampling
Cutting
Analysis (EPI,
PPI)
Warping
Sizing
Drawing
Gaiting/Knottin
g
20cm Lap Dip
Sample

Bulk Production

Weaving Procedure
|

Beam
Getter

Operator

Troubleshoo
ter

Foreman

Weaving Machines
UNIT

TOTAL MACHINES
Airje
t

Rapie
r

Total

WIDTH

WEAVE

FABRIC

BRAND

PRODUCTIO
N

Maintenance
In Alok Industry maintenance of machineries is done by maintenance department. It is of two
types:1. Preventive
a. Cleaning of fluff accumulated in machines as well as oiling of different
parts of the machine Is done to prevent wear and tear and for the
smooth functioning of the machine.
2. Breakdown
a. Providing solution to any kind of problem occurring in the machines
and to fix it after the damage.
Maintenance department is centralized department. There is unit wise maintenance head. And
for 14-15 machines there is one person. The main role of maintenance department is to make
schedule of maintenance and follow the schedule. Consumption of oil is:1. Gear box-1 machines picanol is 2.5 liter/year
2. Cambox -1 machines dobby is 7 liter/year

Utility
This department looks after electrical, electricity, power and compressor (air supply for air jet
looms) in Alok industries. Alok Industries get power from Gujrat Electricity Board (GEB).

Airjet(NW)
Rapier(NW)
Airjet(WW)
Total

Phase-1
412
145
332
889

Phase-2
305
110
570
985

Total
717
255
902
1874

The power consumption is 23MW for weaving. Weaving unit requires 2300 unit per hour and
also there is 5, 20,000 unit per day uses of power. 1m production requires 1 unit power. Usages
of power are:1.
2.
3.
4.
5.

Loom Power-25%
Humidification Plant-205
Copmpressor-45%
Preparatory-5%
Other-5%

Air Consumption:1.
2.
3.
4.

Normal Width-30 CFM 6 bar pressure


Wider Width- 50 CFM 6 bar pressure
Phase-1 Compressor- 9000CFMx4, 3000CFMx1
Phase-2 Compressor-9000CFMx4, 12000CFMx1, 5000CFMx1