Declaration of the student
I, Suku Thomas Samuel, hereby declare that the this organizational study report Organizational Study at Prabhuram Mills is an original study carried out by me, under the guidance of Prof. Sen B Mathes.
The Report does not form a part of any other work submitted to any other institution or university for the award of any other degree, diploma, associateship or other similar title.
CONTENTS
INTRODUCTION
The Indian textile industry is one of the largest in the world with a massive raw material and textile manufacturing base. Our economy is largely dependent on the textile manufacturing and trade in addition to other major industries. About 27% of the foreign exchange earnings are on account of export of textiles and clothing alone. The textiles and clothing sector contribute about 14% to the industrial production and 3% to the gross domestic product of the company. The textile industry accounts for as large as 21% of the total employment generated in the economy around 35 mill people are directly employed in the textile manufacturing activities. Indirect employment including the manpower engaged in agricultural based raw material production like cotton and related trade and handling could be around another 60 million. Prabhuram mills, a cotton spinning mill located in the industrially background district in Alappuzha is one of the units of kerala state textile corporation limited. A government of Kerala undertaking site of the mill is at Kotta Kotta near Karakad Chegannur Kotta is remote undeveloped undeveloped village village in the Mulakkuzha Mulakkuzha panchayath of Chengannur,Alappuzha district, it is industrially and economically a backward area. Nearly 75% of the people of the area belong to the middle and low income group. Unemployment is a ramp act of therearea. Under this circumstances steps taken f or starting a spinning mill was a blessing to the natives of this area. The project received the whole hearted co- operation of the people. They donated lands and came voluntarily to work for the construction of the two roads to the mill site.
OBJECTIVES OF THE STUDY
1. To study about the organization 2. To analyze various functions performed by the various departments in the organization 3. To gather managerial practical experience in an organization 4. To secure practical knowledge regarding the Materials, HIR, Finance, and Technical Services& Production aspect involved in the organization. 5. To know about the actual flow of communication procedure followed in an organization 6. To know the level of degree to which each departments in an organizations interact with each other to accomplish their goals. 7. To conduct an overall estimation of the effectiveness of the existing organizational. organizational.
SCOPE OF THE STUDY
Modern business is dynamic. Even the organization structure may be changes in near future. There the scope for further study about the company is extended due to technology and changing circumstances
LIMITATIONS OF STUDY
1. The officers were bust with their routine engagements; it was rather difficult to spare their time for detailed discussion. 2. It was very difficult to stipulate a time for the workers because they are very busy with their work. 3. Knowledge about some subjects related to the company was very limited
INDUSTRY PROFILE
India Textile Industry is one of the leading textile industries in the world. Though was predominantly unorganized industry even a few years back, but the scenario started changing after the economic liberalization of Indian economy in 1991. The opening up of economy gave the much-needed thrust to the Indian textile industry, which has now successfully become one of the largest in the world.
Since ancient times, Indian Textile industry has been well known for textile goods. In the early nineteenth century the modern textile industry took birth in India when the first textile mill was established at Fort Gloster near Calcutta in 1818 by the British. The first Indian owned cotton mill was ‘The Bombay Spinning Mill’ which was opened in 1854 in Bombay by Cowasji
Nanabhai Davar. This first successful in Bombay was followed by other Indian entrepreneurs who soon established mills at Ahemdabad and Bombay.
The earlier textile mills in India were founded and functioned at Bombay and its surrounding due to a variety of favorable factors. The abundant capital and credit facilities, cheap and speedy means of transport, the existing trade routes with the middle east and China are some of the factors that lead to the concentration of the this industry at Bombay and suburb areas. The progress of the industry was slow in the initial stages. The industry did not witness any steady progress until the independence.
Today, Indian textile industry largely depends upon the textile manufacturing and export. It also plays a major role in the economy of the country. India earns about 27% of its total foreign exchange through textile exports. Further, the textile industry of India also contributes nearly 14% of the total industrial production of the country. It also contributes around 3% to the GDP of the country. India textile industry is also the largest in the country in terms of employment generation. It not only generates jobs in its own industry, but also opens up scopes for the other ancillary sectors. India textile industry currently generates employment to more than 35 million people.
Indian textile industry can be divided into several segments, some of which can be listed as below: • Cotton Textiles • Silk Textiles • Woolen Textiles • Readymade Garments • Hand-crafted Textiles • Jute and Coir
The Indian textile industry contributes about 14 per cent to industrial production, 4 per cent to the country's gross domestic product (GDP) and 17 per cent to the country’s export earnings. The industry provides direct employment to over 35 million people and is the second largest provider of employment after agriculture.
Fabric production rose to 60,996 million sq meters in FY 2011 from 52,665 million sq meters in FY 2007 Production of raw cotton grew to 32.5 million bales in FY11 from 28 million bales in FY07, while production of man-made fiber rose to 1,281 million kgs in FY11 from 1139 million kgs in FY07. Production of yarn grew to 6,233 million kgs in FY11 from 5,183 million kgs in FY07.
India has the potential to increase its textile and apparel share in the world trade from the current level of 4.5 per cent to 8 per cent and reach US$ 80 billion by 2020. Exports of textile grew to USD26.8 billion in FY10 from USD 17.6 billion in FY06. India’s textile trade is dominated by
exports with a CAGR of 6.3 per cent during the same period
Some of the major players in the textile Industry are as follows:
Welspun India Ltd
Welspun India Limited (WIL) is the Flagship Company of Welspun Group with an enterprise value of U.S. $ 3 billion. WIL is ISO 9001:2000, 14001 and SA 8000 certified company. WIL is
a composite textile mill producing Cotton Yarn, Terry Towels and Rugs for international market. WIL is located at village Morai in Valsad district, Gujarat State.
Vardhman Group
Vardhman Group was established in 1965 and is a leading textile conglomerate in India having a turnover of $700 mn. They The y have over 24 manufacturing manufac turing facilities in five states across India.
Alok Industries Ltd
Alok Industries Ltd. is an India-based textile manufacturing company and was established in 1986. Alok Industries is a private textile manufacturing company and has manufacturing bases spread over 6 locations in Navi Mumbai in Vapi and Silvassa, situated in Maharashtra.
Raymond Ltd
Raymond was incorporated in 1925 and has over 60% market share worsted suiting in India. The company has a diverse product range of nearly 20,000 design and colours of suiting fabric. They export their products to over 55 countries including USA, Canada, Europe, Japan and the Middle East.
Bombay Dyeing
Bombay Dyeing is one of the leading companies in the textile business. In fact, India has made a position in the world textile sector holding the hands of Bombay Dyeing. The textile products of the company are exported to different nations all across the world like the United States, European Union Countries, Australia and New Zealand.
COMPANY PROFILE
Prabhuram Mills is a cotton spinning mill owned and operated by the Kerala State Textile Corporation (KSTC). Kerala State Textile Corporation Ltd (KSTC) incorporated in 1972 operating through seven mills spread across Kerala. These seven mills located in different districts of Kerala viz Kottayam, Alappuzha, Kozhikode, Malapuram, Kannur and Kasaragod. The Corporation presently engages 1613(management staff and workers, including 795 workers on contract/ daily wages basis) employees and is proposed to add another 759 employees under its expansion and modernization programmes.
The mill is located at the Kotta, near Karakkad, Chegannur Taluk, Allapuzha district in Kerala. The mill has a long history spread over a span of 40 years. The mill is responsible for processing raw cotton into yarn for later stages of processing in other textile related industries.
Prabhuram Mills at Chengannur
Edarikode Mill at Kottakkal, Thrissur
Malabar Spinning Mill at Malabar
Kottayam Textiles at Kottayam
Uduma Textile Mills at Kasargod
Hi-Tech Weaving Mills at Thalassery
Komalapuram Spinning & Weaving Mills at Komalapuram
KSTC also has a testing facility – CARDT, Centre for Applied Research and Development in Textiles. It is the only fully equipped testing laboratory available in the state of Kerala, catering to the testing needs of the mills in Kerala.
The village of Kotta is a remote and an underdeveloped village at the Milakuzha panchayat of Chengannur taluk. It is an industrially backward village. Nearly 75% of the population here belongs to the middle and the lower income class. The mill has been a blessing in lifting the economic backwardness of the locality and providing livelihood for many people here.
The establishment of the spinning mill at Kotta was the outcome of the industrialization efforts of the Government of Kerala. The Govt. of Kerala carried out a techno-economic survey during the year 196061. It was conducted under the leadership of P.S Lokanathan between February 1960 and September 1961. The report which was finalized in July 1962 contained a detailed study of the economic development of Kerala. While the survey was being conducted, the Kerala Government declared its first Industrial Policy on 3 rd June 1960. The declaration was to enhance the development of the economically backward area of the stated. The declaration gave provision to entrepreneurs’ access to various facilities to establish industries. The policy also attracted many entrepreneurs’ outside the state as well. The then Tamil movie star, Shivaji
Ganeshan and VA Muthumanikkam an industrialist from Pollachi decided to make the most out of this opportunity.
Shivaji Ganeshan and VA Muthumanikkam entered into an agreement to set up a textile mill. Since Tamil Nadu had a lot of textile mills, procuring a license was difficult. They identified Kotta at Chegannur as a suitable location. This was because of the f ollowing reasons:
Cheap Land
Continuous and cheap sources of power
Availability of water
Suitable climatic conditions
Transportation and communication facility
Availability of cheap labor
Access of cheaper finance option
Support of local community
The land rates at Kota were very minimal making way to procure large plots suitable for industries. The rates were as low as Rs 20 per cent back in 1962 making it possible for the company to procure around 14 acres of land for the company. The Kerala government committed the management adequate power to the newly established industries from Chengannur and Kozhencherry substation assuring a continuous supple of power. The textile industry required large quantities of water supply. Since Kotta had no scarcity of water, the location proved to be suitable. The climate was also favorable for textile industry. The location provided easy access to both rail and road means of transport. The Kerala government for the want of industrialization in remotely underdeveloped areas made loan facilities available through KSIDC and
KFC. Kotta was eligible for these loans. The local community welcomed the industrialists with extended support. The land was offered to the management at cheap rate in return of assures appointments at the mill.
The industrialist, Shivaji Ganeshan and VA Muthumanikkam decided to name the industry Prabhuram Prabhuram Mills. The name was conceived from the Shivaji Ganeshan son’s name ‘Prabhu’ and VA Muthumanikkam son’s name ‘Ram’. The objective for which the company was established was to
purchase textile raw materials such as cotton, jute, hemp etc and process them into fibrous products. The management commenced with an initial capital of 50 lakhs. The machinery required for the firm was ordered from Japan and Tamil Nadu. The management was awarded license on the 12 of May 1962. The mill was initial awarded a license of twelve thousand spindles and was later increased to 25 thousand spindles.
14.28 acres of land was procured by the year 1963. By the beginning of 1964, the construction of the mill building started. However, Shivaji Ganeshan backed out of the agreement unexpectedly on 17 of October 1964. The project came to a gridding stop by 1965 due to lack of finance. In 1969, KSIDC came to the rescue of the project. By April, 1973 the project was reconstituted and continued. The project was shut down in 1975 due to financial problems. After much struggle and strikes by the local community, Prabhuram mill was taken over by the Government of India under the Ministry of Industries in 1978. On 29 April 1984, the mill was acquired by the Government of Kerala and was transferred to the management of Kerala State Textile Corporation C orporation (KSTC).
PRODUCT PROFILE
In the cotton textile Industry, the main raw material is cotton which is converted into yarn and yarn is later processed to produce cloth. Cotton is the most widely used textile fiber today. Some of other fibers include jute. The scientific name of plant from which cotton is obtained is called Gossypium. The chief cotton producing countries in the world are USA, India, Brazil, China, Pakistan and Egypt.
After cotton has been harvested, the kapas has to be ginned in order to seperate the fiber from the seeds. Cotton, after ginning is available in loose opened f orm. For ease of handling and transportation, the cotton is compressed and packed into bales. The bales are covered by jute sacking and bound by strong wire or iron bands. The textile mill gets the cotton in the form of pressed bales. The quality of cotton is judged in terms of its grade and staple. The grading is done on the basis of impurities such as leaves, sand, dust, broken seeds, neps and colour. The quality of the cotton fiber is judged mainly by the length of the fibre. Quality of cotton depends on its physical properties namely length, finess, strength, maturity etc.
The conversion of cotton into yarn is done in a spinning mill. The spinning is the practise of twisting in which a number of loose fibers are bound together to form a single large strong fiber. This is later spun to form the yarn.
PRODUCTION PROCESS
Various operations are carried out in the mill in the different sub departments to yield yarn from cotton. The various sub process involved in production are as follows
Mixing
Blow room
Carding
Drawing
Simplex
Spinning
Winding
Packing
MIXING
Cotton being a natural fiber has unique properties of its own. It is characterized by good water absorbency, skin comfort, durability. Synthetic fibers are known for its strength, luster. When natural fiber is mixed with synthetic fiber, it improves the overall properties of the fiber.
In the mixing process, the cotton fibers are mixed with synthetic fibers in the ratio of 80:20. The synthetic fiber and cotton fiber are mixed thoroughly to get a uniform blend. The objective o mixing is to obtain a near as possible uniformity in length, quality and color.
BLOW ROOM
This process is performed only during the day shift. The machineries are of utmost importance in the Mill. The blow room line consists of opening, cleaning, mixing and lap-making machine.
The first process in the blow room is opening of the hard pressed bales and cleaning of the cotton for heavy impurities like broken seeds, leaf, stalk, husk, sand. Foreign matter has to be extracted from with cotton with least waste.
Scotching and lap formation are use last operations in the blow room. Although the cotton has now passed through the opener and has most of impurities separated, it still needs to be cleaned further. The cleaning process is therefore continued in scotching. The objective of scotching is to remove as much as impurities as possible the opener failed to expel. The loose cotton passes through the sketcher and is converted into uniform sheets called laps. These laps are then delivered to the next department called carding.
CARDING
This is the second and the most important department in the spinning mill. There are fourteen cards and the carding department functions in three shifts. The objectives of carding process are:
1. Waste removal: this is to remove the impurities and clean the cotton further. The main wastes extracted from the cotton in the carding department are
a. flat strips b. Linker in wastes c. Cylinder waste d. Pneumatic waste
2. To remove the short fibers, bits of seed, leaf, naps etc from the laps so that better yarn may be produced as far as possible
3. To lose the fibers and separate them so that the work of the draw frame (which is to make them parallel) maybe effective.
4. Individualization Individualization of the fibers and convert them into single strands (thin fibers) called slivers.
5. The slivers can be stored in cans. The carding process helps a thorough mixing of the fibers.
DRAWING
In the drawing process, the carded slivers are processed. There are three drawing machines in the department. The objective of the drawing process is to:
Blending of slivers
Attenuate of fibre
Parallesation of fibres
Improvement of uniformity of sliver
Purification of sliver further
The carded slivers are passed through two drawings namely the braker drawing and the finisher drawing.
Drawing Process
The carded slivers in eight cans are placed on the back of the drawing head. The slivers from the cans are then passed through a guide and four pairs of drawing rollers. The purpose is to attenuation of drawing out of the fibers. The slivers from these eight cans become one after the other process and pass through the rollers to a coiler which coils the new slivers into a can. This sliver can in now ready for the next process.
SIMPLEX
There are six simplex machines, three 120 spindle and three 124 spindle machines. The object of the simplex is to convert the carded and the combed slivers into roving. The carded slivers and supplied to the simplex machines. Here the slivers pass between three lines of rollers where it is subjected to drawing action. A slight twist is given to the attenuated and is sufficient to give the necessary strength to enable it to build around the bobbin. In this condition it is convenient for further treatment. The roving wound on bobbins is supplied to the next department.
SPINNING
The spinning is the last stage in the manufacture of the yarn. The spinning frames are convert the roving into the yarn of the required count. The main operation carried out in the ring frames are drafting, twisting and winding. The roving received from the simplex department is still much thicker than the thickness of the final yarn required. Therefore the first process on the ring frame is drafting. The next operation is twisting. The amount of twist inserted here is larger than any other previous stage in order to give sufficient strength for the end use required. These are fitted upon spindles which run at a speed of about 13,000 to 16,000 rpm.
WINDING AND PACKAGING
The winding machines are for removing the defects like thick and thin places in the yarn and to enhance the length.
Here the cop wound yarn from f rom the ring frame in the spinning department is transformed to conical shaped mass of wound on paper cones weighing 1 kg. The cops are fixed firmly on spindlier at the bottom of the winding machine in length wise. Yarn is then passed though the guides and catchers and wound on paper cones.
The winding process is continued by combining the length of the yarn from a number of spinning cops. Mechanical types and electronic cleaning devices are used in winding machines with a view to remove objectionable thick places like slobs, bad piecing or knots from the produced yarn. The comers are then packed into bags. The net weight of a bag is 50 kg
DEPARTMENT PROFILE
Departmentalization is a part of the organization processes it grouping the common activities under a single individual’s control. The activities are grouped on the basis of function of the organization. The
work is done by a chief executive of the concerned organization. It is an essential one on the modern business world. A single individual cannot look after the business activities. The classified activities bring in specialization. The overall management of the affairs of company vests with the chairman and managing director. The top executive at Prabhuram Mills the general manager who reports directly to the chairman and Managing director. The organizational structure of Prabhuram Mills shows a more or less linear structure without many Departments.
FINANCE DEPARTMENT
The finance department deals with coordinating audits like internal audits, cash management, statutory audit, budgeting. The Finance Department is an exception in terms of reporting as the department reports directly to the Finance Department of KSTC under the supervision of the Mill General Manager.
ASSISTANT MANAGER - FINANCE
The Finance assistant manager is responsible for managing and supervising the overall financial and accounting activities at Prabhuram Mill. The Finance manager reports directly to the General Manager of Finance at KSTC and indirectly to the Mill General Manager.
The Finance Manager is responsible for the following areas:
Internal audits
Income tax audits
Cost audits
Statutory audits
Compliance with the KSTC standards and procedures
Budgeting
Approvals
Supervising the subordinates
CASHIER
The cashier is responsible for all transactions related to cash. The cashier's responsibility includes handling of the cash, verification of the daily cash balance, updating the entries into the petty cash book and posting entries into the ledgers. At Prabhuram mills for updating and maintaining accounts on the system, the software 'Tally' is used. Payment of wages, overtime, bonus etc to the employees is done in cash.
The key responsibility areas of the Cashier are as follows:
Maintaining all cash transactions
Daily verification of cash balance
Updating entries on the Petty Cash book
Posting the entries from Petty cash book to ledger
Payment of wages
Maintenance of unpaid wages and payables.
Tracking cash collection transactions - cheque and draft deposits.
Forecasting the daily, weekly and monthly cash requirements at the M ill
Dispensing cash for Mill payables and requirements - telephone, stationary, electricity etc.
Maintenance and tracking of Mill assets.
Audits on wages computation
SENIOR ACCOUNTS ASSISTANT
The senior accounts assistant at Prabhuram mill is responsible for maintenance of all statutory accounts. The statutory accounting includes the preparation of reports and records as per the Income tax and Factories act prevailing in the country. It includes mainly the computation of Sales and income tax, maintaining of records for Government reporting activities.
The key responsibility areas of a senior accountant ac countant are as follows:
Preparation of monthly/ quarterly/ half yearly and annual trial balance a nd balance sheets
Monthly reconciliation stocks, stores and spares.
Preparation of fixed assets registers
Preparation of weekly, monthly, quarterly, half yearly and annual sales and returns reports
Checking and verifying vouchers
Verifying all documents and invoices of dispatch and sales
ACCOUNTS MIS ASSISTANT
Prabhuram Mills maintains a number of reports for internal and external reporting needs. The internal stakeholders are the senior management, production department and the Human resource department. The external stakeholder includes the KSTC, various government bodies such as Income tax department etc and the customers. Thus the Mill lays a lot of emphasis on the reporting activities. The mill has dedicated
personnel to meet all the reporting and MIS needs. From time to time, depending on the reporting requirements, the various templates are designed. The mill uses a combination of Tally and Excel spreadsheet to meet the MIS and reporting needs of the company.
The key responsibilities of the MIS Assistant are
Preparation of all cost records and making statements and reports related to costing and accounting
Preparation of budget and analysis of actual performance
Verification of staff acquaintance rolls, wages records
Calculation of staff and workers advance, bonus, gratuity
ACCOUNTS ASSISTANT
Preparation of bank vouchers and bank book
Maintaining cheque issue register
Prepare monthly bank reconcilation statement
Preparation of monthly cash flow statement
Send the returns of Sales tax, Income tax and other tax and arrange the remittance of those in time
Preparation e final accounts and related statements at the time of audit
Raising of insurance claims as and when required
Preparation of deferred payment guarantee documents as and when required
CLERK
The Finance department has an clerk to support the activities. The key responsibilities of the attender are as follows:
To assist the others at the department on the day to day activities
Attending to the banking needs of the mill
Coordinating the tax deposit and other statutory activities of the mill
Handling the reports
Filing and storing of important financial documents
Assisting in physical inventory taking for recording purpose
PERSONNEL DEPARTMENT
The Personnel department at Prabhuram Mills is a very dynamic department. The P ersonnel department is the key to ensuring a smooth functioning of the mills activities. The department is responsible for all human resource related activities at the Mill. This includes
Hiring
Training
Transfer and Exit formalities f ormalities
Human resource reporting and MIS
Employee workers welfare
The structure of the Personnel department is as follows
The department is headed by a Personnel Manager. The directions for the departmental functioning are provided by the Personnel manager. The manager acts according to the policies and regulations lay down by the Kerala State T extile Corporation.
PERSONNEL MANAGER
The Personnel department is headed by the Personnel manager. In the absence of the General manager at the Mill, the Personnel manager assumes responsibility to ensure a smooth functioning of the Mills activities. The Personnel manager is responsible for all Human Resource related activities at the Mill.
The Personnel manager performs the following function:
Plays the role of a team leader
Receiving staff and employees to the organization (Induction and orientation) orientation)
Identify training needs
Organizing and conducting training programs at Prabhuram Mill
Performance appraisal for employees and workers
ASSISTANT MANAGER – Training
Prabhuram Mills is involved in production of yarn from cotton. The production process involves a number of sub processes to get yarn. Training is an essential and critical function at the Mill. Training requirement can be broadly divided into the following:
Training needs for new joiners
Cross training for tenure workers
Training on quality and production improvement initiatives
The Assistant manager is solely responsible for all training activities at Prabhuram Mills. The responsibilities of Assistant Manager for training are as follows:
Organizing training for new joiners at the Mill
Organizing cross training for tenure workers on completing tenure at a production sub process
Monitoring the progress of trainees
Organizing special training at the Mill such as improvement and quality initiatives
ASSISTANT - Time Keeper
The Assistant - Time keeper at the Personnel department plays a key role in terms of payroll and attendance tracking. The responsibilities are as follows:
Preparation of workers’ wages and salary for staff
Maintaining the attendance tracker for all employees at Prabhuram M ills
Preparation e abstract of salary and wages statement
Preparation of advance register
Calculation of gratuity allowances
Preparation of annual leave register and forms
Assisst Personnel manager in preparation of orders off transfer, promotion, offer letter
Tax computation based remuneration of the employees
ASSISTANT - ESI & PF
Payroll computation is one of the biggest activities at the Personnel Department. The ASSISTANT - ESI & PF is responsible for the following:
Preparation of returns to be sent to various authorities such as Inspector of factories, ALO, DLO, Head office
Preparation of necessary records for the proper and timely remittance of T.D.S for employees
Calculation of Provident Fund for the staff and eligible workers
Deposit of PF amount with the Provident Fund office
Processing PF withdrawal request to the PF Office at Ernakulum
OFFICE ATTENDER
The Personnel Department has an Office at tender to assist them in the departmental activities. The responsibilities of the office attender are as follows:
Distribution of incoming mails, telegrams and other correspondences
Delivering of Office orders, charge sheet, affixing notice
Hand delivery of letters to various persons and offices outside the mill as per instruction
Local purchase of material as per requirements
Filing of papers in concerned files and folders
Attending to the banking needs of the mill as per instruction of the management
Attending to the office telephone
Any other work assigned by the management from time to time
TECHNICAL DEPARTMENT
The Technical Department at Prabhuram mills forms the largest department. The department is the most crucial and important part of the mills functioning. The Technical department at Prabhuram Mills is dividend into the following four sub departments:
Production
Quality Control
Maintenance
Electrical
PRODUCTION DEPARTMENT
The Production Department is the key to functioning and the existence of the Mill. It is otherwise called the Manufacturing or the Operations Department. The Production Department is required for transforming raw materials and finished materials into finished products. The department is solely responsible for controlling all activities related to production.
The structure of the production department is as follows:
ASSISTANT MANAGER – PRODUCTION
The ASSISTANT Manager for Production supervises the entire functioning of the Production department. Since the production at Prabhuram Mills is carried around the clock, the Mill operates in 3 shifts. Each shift has an Officer in charge.
The responsibilities of the AM Production is as follows:
Monthly Production forecast
Planning of weekly and daily production
Preparation of workers shift schedules
Coordinating and managing stocks with the maintenance department
Supervising production activities at the Mill
Managing and checking the machinery at the Mill
Managing and planning for any contingency situations if any
SHIFT IN-CHARGES
Prabhuram Mills conducts production activities around the clock. The Mill operates in three shifts. Each shift has a Shift in-charge to manage the production activities in a particular shift.
The responsibilities of the shift in charge are as follows:
Assisting the AM-Production in al production related activities
Planning and supervising production activities through a shift
Ensuring attendance of the scheduled employees
Tracking the raw material consumption during a shift
Recording production output during a shift
PRODUCTION CLERK
The Production Clerk plays an important role in Production MIS. The responsibilities are as follows:
Verifying shift reports
Completion of daily production statement
Calculation and recording of reports related to spindle utilization, spinning efficiency etc
Recording daily utilization of workers and machinery
Verifying employee attendance
Notifying list of absentees to the management
Recording machinery breakdown
Recording and reporting any production down time
QUALITY CONTROL DEPARTMENT
Prabhuram Mills lays a lot of emphasis on quality. Quality is an important factor as it determines the quality of products produced by the mill.
Prabhuram mill has a stringent set of practices that ensures quality compliance. The company has an inhouse quality department and an external independent body to confer the quality of goods produced.
The quality tests that are conducted by the Mill are as follows:
RAW COTTON TEST
Raw cotton test is an important quality test that is performed to ensure the quality of cotton purchased. Since the cotton is purchased from the supplier and is an important direct factor is determining th quality of the yarn produced.
Through the raw cotton test the quality of the cotton received from the supplier is determined and graded. The factors that determine the raw cotton are 1. Length of the fiber 2. Fitness in micro grams per inch 3. Uniformity ratio in percentage
It is equally important to perform quality test on the yarn that is produced. The quality of end product is a necessity in meeting customer expectations. Random samples of the yarn are drawn and the following tests are performed:
TWIST TEST
The twist test is important as the t he number of twists present in the yarn produced determine the strength and tensile strength of the fiber. The twist test helps in determining the number of twist per inch of the yarn produced.
Apart from the inhouse quality test, random samples of the yarn produced are drawn at regular intervals and sent to the CARDT for testing.
ASSISTANT MANAGER – QUALITY
The quality department is headed by the ASSISTANT manager. The manager is solely responsible for all quality related activities at Prabhuram Mill. The responsibilities of the ASSISTANT manager for quality are as follows:
Planning and organizing quality initiatives at Prabhuram mills
Conducting quality related training for the mill workers
Implementing quality practices at the production process
Monitoring quality practices during the production process
Preparing quality reports for management
Ensuring compliance with the industry and product standards
Devising new strategies for quality improvement
Monitoring the functioning of the quality analyst
QUALITY ANALYST
The quality analysts play a key role in quality compliance. The responsibilities of the quality analysts are as follows:
Drawing random samples of raw cotton and produced yarn
Performing the quality tests
Recording the quality test results
Assist the AM Quality in all quality related activities at Prabhuram Mi ll.
Coordinating external quality tests
Communicating and identifying new opportunities for quality improvement
SWOT ANALYSIS STRENGTH Support of the Government Prabhuram Mill is operated by Kerala State Textile Corporation which is a government body. The mill enjoys the favourable government support.
Easy access to sources of funds Prabhuram Mill enjoys access to sources of funds from Kerala State Financ Corporation, KSTC at a subsidy rate.
Access to power at cheaper rates
Availability of land assets
WEAKNESS The weakness that the company faces can be listed down as f ollows:
High labour absenteeism Outdated technology Over stocking of raw material Lack of vision by the management. Lack of working commitment from employees
OPPORTUNITIES New market explorations Prabhuram Mill can setup a inhouse marketing department for new market exploration and competitive marketing strategies
Upgradation of machinary and production technology for better product output.
Expand the existing factory Prabhuram Mills has ready access to the required resources - capital, land and human resource for expanding the exisiting plant.
Increase line of products Prabhuram mills has access to the required resource for increasing its exisiting line of products
THREATS Competition in the market High cost of raw material
CONCLUSION
I had great pleasure in completing the organizational study at Prabhuram Mills. I also concede that the study has showered great insights into the application and working of management principles and practices. The firm is a rapidly growing company. Its is a outcome of hard work and the efficient skill revealed a the General Manager and his staff. The firm has contributed to the social and economic upliftment of the locality. It has also contributed to the overall industrial development of the state. A greater level of prosperity awaits Prabhuram Mills and its management.
