08BBA48

JOY POLYFAB PVT. LTD.

INDUSTRY PROFILEAccording 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 4th century ad, cloth colored with Tyrian purple was the symbol of royalty.The art of dyeing was stimulated in the 13th 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 16th 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 PROFILEWith 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.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 raw-material 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 RESPONSIBILITYResponsibility 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.2. Technology up gradation.3. Improvement in quality.4. Reduction in damage Percentage.5. Setting a New Cotton Plant.6. Weaving plant.COMPANY DETAILPARTICULARSINFORMATION

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:[email protected], [email protected]

Tel:+91-260-2421890

Fax:+91-260-2435290

COMPANYS EXECUTIVE SUMMERYNAMEDESIGNATION

Shri Pershotambhai GolkiyaPromoter

Shri Bhupendra GolkiyaDirector

Shri Arvind GolkiyaDirector

Shri S.P. SvaniDirector

Shri Umesh MaroliyaProduction Department

Shri Rajesh TundonMarketing Department

Shri Manoj ShahFinance & Accounting

Shri Rajesh PatelPersonnel & HR

Shri Arvind GolkiyaCollection

Shri Yogesh GolkiyaPurchase

Shri Pravin PatelMaintenance & Engineering

Shri Umesh MaroliyaDress & Suiting Department

Shri Somnath KakdeLaboratory

Shri JayramPackaging & Finishing Goods Store

Shri JayramPackaging & Finishing Goods Store

Shri Raju PatelCashier

ORGANIZATION STRUCTURE OF JOY

INDUSTRIAL MARKETINGDifferent 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.

MarketThe 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.MarketingMarketing 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.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

CLACIFICATION OF PRODUCTJOY 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

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

SALES VOLUMES & SALES FORECASTINGSales 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 IN METER PER DAY200720082009

SALES135,256,336141,648,235149,273,679

CLOSING STOCK1,965,2262,786,7941,473,313

OTHER INCOME134,653,222144,154,716152,310,866

PROCESSING CHARGES132,223,679135,033,624140,981,767

TOTAL404,098,463423,623,369444,039,625

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.

CUSTOMER SEGMENTATION & TARGET MARKETCustomer 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 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.UNIQUE FEATURES OF PRODUCTJOY 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

DEMOGRAPHICS

(a) Age:

Different people have different taste and preference. JOY cater to the needs of all age of male and female. (b) Gender:

(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

COMPETITORSCompetition 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)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 COMPATITORSMarketing 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 :

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).

PriceThe 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. PromotionMarketing 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 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. 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 4PsThe 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 5th 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)JOYCHIRIPAL

ProductGood quality with higher product mix. They believe in use of new technology for their product.Good quality

PriceComparatively slightly higher then ASlightly lower then JOY

PlaceVapiAhmadabad

PromotionSpends higher comparativelyLarge variety serves it indirectly

Packaging(5th P)More flexibleFlexible

PRICING POLICYJOYS pricing policy depends on:

1. Manufacturing cost

2. Marginal cost

3. Competitor Rates

4. Competitor Quality5. Market Requirement

6. Customer Focus

PROMOTION & ADVERTISEMENT POLICIESAdvertisementAdvertising 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.

REPORTS IN MARKETING DEPARTMENT: 1. Daily Grey inward report

2. Daily dispatch report

3. Daily payment collection report

DOCUMENTS RELATED TO SALE:1.Challan2.Gate pass

3.Invoice

4.Dispatch Order

5.Price list

PRODUCTIONProfessor 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 MANAGEMENTManagement 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, co-coordinated 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.

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 helps to satisfy the need of customer timely.

It increases the productivity of organization.

It gives better satisfaction to the employees.

It 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.PRODUCTION HOD

(Umesh Moraliya)

Shirt

`Dress

New Dyeing

Dyeing Master

Assistant Dyeing Master

Supervisor

Asst. Supervisor

Jet

Stenter

PaddingDrumming

Incharge

Operator

Helper

Jobber

(For Dress and New Dyeing)

PREPARATION OF PRODUCTION PLAN FROM SALES PLANProduction 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.

Material requirement planningMaterial 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.

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 PLANNINGMaterial 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 scheduleMps 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 fileAll 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 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.

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 PLANAs 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.

Analysis of plant locationIt 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

Cost of land

Taxes liberalization

Government other incentives

Nature of production operationANALYSIS OF PLANT LOCATION1. 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- OUTPlant 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.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.i. Job Shop Type, andii. 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.PRODUCTION PROCESS

TERMS RELATED TO PRODUCTION PROCESSGREY 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.

JET

On jet fabric that is on the grey stage or after drumming is scoured, bleached and white or dyed. Jet is1. 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.

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}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.STENTERStenter 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.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.

{Figure: Mangle Machine}PADDINGImpregnation 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.

UTILITYUtility 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, 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.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 EQUIPMENTSThe 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. Platform Truck Electric Stacker Drum-Trolley Luggage trolleyTYPES 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 equipmentsJOY 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 materialAccording to this classification there can be three broad categories, solid material, liquid material and gases.JOY use hand carts, trolleys like DRUM-trolly 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 movementJOY 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 automationThere 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.Classification on the basis of source of powerEquipments 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

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 analysisABC 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

A7010

B2535

C555

Item according to different category:ACLASSB-CLASSC-CLASS

Acrylic DyesFeSO4Micro Metallic Trolley

HydroStain RemoverSetting Handle

CausticLime(Soda ash)

FSN ANALYSIS:F: means fast moving items

S: means slow moving items

N: means non-moving itemsFASTSLOWNON-MOVING

Citric AcidDis. Blue 2RXNo item is there which is non-moving

Acetic AcidDis. Blue D2R

Golden Yellow GGBrasso Solution

Navy Blue 3GPure NID

Blue SR, Red F3 BS

VED ANALYSIS:V: Vital itemsE: Essential items

D: desirable itemsVITALESSENTIALDESIRABLE

BearingOilSponge

Electronic partsLubricantsconveyer

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.

FINANCIAL MANAGEMENTFinancial 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.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

BUGDETINGAs 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.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.

WORKING CAPITAL MANAGEMENTWorking 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.PERTICULER200720082009

CURRENT ASSETS33,549,74032,949,54635,986,495

CURRENT LIABILITES28,446,31924,852,46527,075,007

WORKING CAPITAL5,103,4218,097,0818911458

ACCOUNTING POLICIES FOLLOWDAccounting 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.

INVENTORY VALUEATION & CONTROLINGThe 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 DEPRECIATIONAt 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. Uniform charge methods.2. Declining charge or accelerated depreciation methods.

3. Group depreciation method.

4. Inventory system of depreciation.5. Annuity method.

6. Depreciation fund method.7. Insurance policy method, etc.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 STATEMENTSCommon 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 ANALYSISIn 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.PRESONNEL MANAGEMENTPersonnel 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.

HUMAN RESOURCES PLANNINGHuman 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. PLNNINGThe 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.

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 requirementsThe 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) 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 & INDUCTIONOnce 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.RECRUITMENTRecruitment 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 recommendationThrough above mention sources the company gets application. After that Mr. Ramesh patel with respective HOD weed out the unsuitable candidates.INDUCTIONInduction 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 co-workers, his job positioning, his salary, his safety equipments, etc.

JOB DESCRIPTION & SPECIFICATIONA 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 DESCRIPTIONIt 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 TECHNICIANDyeing 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.

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

HOURS AND ENVIRONMENTHours 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 SPECIFICATIONJob 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.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 peopleWORKER 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

PERFORMANCE APRRAISALAccording 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.EMPLOYEE WELFARERapid 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

Training and development programs

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.

TRAINING AND DEVELOPMENTTraining 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.TRAININGTraining 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 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 POLICYCubin 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.

WAGE & SALARY ADMINISTRATIONEmployee 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.FINDING AND RECOMANDATIONFINDING 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 step-by-steps so they are increase their capacity to produce per day production.

recommendation The company should increase their share out. 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.

CONCLUSIONDuring 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.

Year

JET MACHINE

Customers

Customers

Customers

Customers

Customers

Promotion

Place

Price

Product

Marketing mix

COLLECTION

PAYMENT

COLLECTION OF ORDER

CUSTOMER RELATION

Marketing department

Banking

Account

Time Keeping

Insurance

Assi.Manager

Assi.Manager

Purchase

Store Keeping

Purchase

Store Keeping

Maintenance

Color & Chemical

Production manager

Customer Relationiion

Collection & Payment

Production

Marketing

Purchase

Finance

Managing Director

ANALYSNG THE PRESENT STOCK LEVEL

PREPARATION OF PROGRAMME FORM

PRODUCTION PROCESS

PACKAGING

TRANSPORTATION

GREY

STITCHING

PADDING(Dyed in 2 or More diff. color)

JET (Bleaching/dyeing or Scouring)

WASHING

MERSERIZING & NEUTRILIZING (Washing)

STANTER (Finishing) ssssSTANTERSTANTER(fINISHING

FOLDING (Checking) ssssSTANTERSTANTER(fINISHING

PACKING

DISPATCHING

PRODUCT

SHIRTING

SUITING

DYEING

VAT DYEING

DYEING

DISPERSE DYEING

DOUBLE DYEING

REACTIVE DYEING

VAT DYEING

DOUBLE DYEING

REACTIVE DYEING

DISPERSE DYEING

LOCATION

NATIONAL

INTERNATIONAL

EAST

WEST

NORTH

WEST

EAST

SOUTH

SOUTH

NORTH

PRODUCT

SUITING

SHIRTING

DYEING

DYEING

MANAGER

ACCOUNTANTS

COLLECTION OFFICER

LEGAL ADVISOR

TAX CONSULTANTS

Banking

Account

Insurance

Time Keeping

Assi.Manager

Assi.Manager

Store Keeping

Purchase

Store Keeping

Purchase

Color & Chemical

Maintenance

Production manager

Collection & Payment

Customer Relationiion

Finance

Purchase

Marketing

Production

MANAGING DIRECTOR

VERTICAL JET

HORIZONTAL JET

52

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