1. Department: BLOW ROOM Process flow chart: I NPUT: Cotton Mixing PROCESS: The purpose of blow room process is to open, removal of heavier impurities present and clean the cotton and make it a continuous sheet with uniform predetermined weight per unit length. It is wound on a lap rod for feeding to the carding. OUTPUT: Lap weight = 23 kgs (including lap rod) Length = 49m MACHINE: 2. Department: CARDING Process flow chart: INPUT: Blow Room lap PROCESS: During carding process the blow room lap is opened, cleaned and neps are removed, fibers made INPUT GBR AXIFLOW STEP CLEANER VISION MULTI MIXER SCUTHER OUTPUT INPUT FEED ROLLER LICKER-IN CYLINDER DOFFER OUTPUT
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1. Department: BLOW ROOM
Process flow chart:
INPUT: Cotton Mixing
PROCESS: The purpose of blow room process is to open, removal of heavier impurities present and clean the cotton and make it a continuous sheet with uniform predetermined weight per unit length. It is wound on a lap rod for feeding to the carding.
OUTPUT: Lap weight = 23 kgs (including lap rod)
Length = 49mMACHINE:
2. Department: CARDING
Process flow chart:
INPUT: Blow Room lap
PROCESS: During carding process the blow room lap is opened, cleaned and neps are removed, fibers made parallel & individualized, required amount of waste is extracted and assembled in the form of sliver with a uniform predetermined weight per unit length and collected in a can in a coiled form for feeding to sliver lap machines.
PROCESS: During the process of sliver lap, a definite no. of card slivers are doubled, drafted and wound as a sheet of lap with uniform weight per unit length on a spool for feeding to ribbon lap machine.
OUTPUT: Sliver Lap
MACHINE:
4. Department: RIBBON LAP
Process flow chart:
INPUT: Sliver Lap
PROCESS: During ribbon lap process a definite no. of sliver lap machine laps are doubled, drafted and wound as a sheet of lap with uniform weight per unit length on to a spool for feeding to comber machine.
OUTPUT: Ribbon Lap
MACHINE:
INPUT CREEL DRAFTING ZONE OUTPUT
INPUT LAP STAND DRAFTING ZONE FEED TABLE
OUTPUT
5. Department: COMBER
Process flow chart:
INPUT: Ribbon Lap
PROCESS: The object of cotton combing is to remove short fibers, minute impurities, neps & fibers made parallel & assembled in form of the sliver. No. of such slivers are drafted and stored in cans in the form of sliver. The sliver has definite weight per unit length & collected in a can in coiled form for feeding draw frames.
OUTPUT: Comber Sliver
MACHINE:
6. Department: DRAWING
Process flow chart:
INPUT: Comber Sliver
PROCESS: The purpose of drawing process is to double a definite no. of slivers & drawn them together to make the sliver more even & parallelize the fibers. The sliver is stored in cans or coiled form for feeding to simplex machines. Auto leveling on weight per meter is tacking place while passing through the machine.
OUTPUT: Drawing Sliver
MACHINE:
INPUT CREEL SCANNING ROLLER ROLLER
DRAFTING ZONE
OUTPUT
INPUT FEED ROLLERS COMBING ZONE FEED TABLE
DRAFTING ZONE OUTPUT
7. Department: SIMPLEX
Process flow chart:
INPUT: Drawing Sliver
PROCESS: The object of simplex or speed frame process is to attenuate the finisher draw frame sliver into a finer strand, twist and wind it on a plastic tube suitable for feeding to ring spinning machines.
OUTPUT: single/double yarn
MACHINE:
8. Department: AUTOCONER WINDING
Process flow chart:
INPUT: Single/Double yarn
PROCESS: In the autoconer winding process yarn from ring spinning/doubling etc. in cop form fed and converted into a cone package of definite weight per unit length during this winding process. The objectionable faults in the yarn are removed by electronic yarn checker (EYC). The cut ends are joined by a splicer & taken onto cones as a continuous length of yarn. The yarn may be waxed, if required, during this process.
OUTPUT: Yarn in cone form
MACHINE:
INPUT CREEL DRAFTING ZONE FLYLER WIND ON
BOBBIN OUTPUT
INPUT MAGAZINE COP HOLDER EYC (With (OR) without contamination clearing)
PAPER/PLASTIC CONE OUTPUT
QUALITY POLICY
GTN IND. Ltd would achieve the highest level of customer satisfaction
by their stated & perceived requirements, maintaining consistency &
timely delivery.
GTN Endeavours continual upgradation of product quality &
technology supported by R&D efforts in a cost-effective manner.
To meet the changing global demands & stay ahead in competition.
GTN would adapt/innovate methods in its manufacturing activity.
GTN would inculcate a sense of quality awareness at all levels by
using appropriate training and motivation techniques.
GTN would aim at preserving the environment conditions by adapting
eco-friendly measures in its manufacturing & other activities.
PURCHASING PROCESS:
1. Selecting the suppliers depending upon the ability to supply the product
with organization requirements.
2. It also includes criteria for selection, evaluation, re-evaluation.
3. Records of supplier evaluation, rating & the necessary follow up action.
PURCHASING INFORMAYION:
Org have documented information to describe product to be purchased include
require for approval, required for qualification of personnel, where necessary &
other related information.
The documentation also specifies the need for ensuring adequacy
of specified purchasing information before placing order with the supplier.
Verification of PURCHASED PRODUCT:
The organization has documented the methods for verification of incoming
products. The type and level of verification may vary depending upon the effect
of the purchased product on sequent product realization or the final product.
In case the organization required to perform verification at the
supplier’s premises, the necessary verification arrangements are previously
agreed upon including the methods of product release.
IMPROVEMENT:
The organization Endeavour to continually improve the effectiveness of
QMS(Quality management system) through the following.
Quality policy & objectives
Internal quality audit results
Analysis of data
Corrective and preventive actions
Management reviews
Customer feedback reports
CORRECTIVE ACTION:
The organization established a procedure to deal with corrective action to
eliminate the cause of non-conformity.
This “intern alia” include review of non-conformities, determining
the cause of non-conformities evaluating the need for action to ensure these do
not occur, determining & effectively implementing the actions and recording the
actions taken.
Actions taken are reviewed for effectiveness.
INTERNAL COMMUNICATION:
The organization realizes that internal communication plays a vial role ensuring
the smooth & effective functioning of the QMS. The organization ensure that
information required to be communicated to persons who need to have then are
effectively done. A separate procedure addressing the means for this has been
established.
MANAGEMENT REVIEW:
The management of the organization conduct management reviews once in
every month. The reviews ensure that the system is effectively functioning , is
suitable adequate & serves the purpose in view. The review also addresses the
opportunities for improvement as may be brought in from different
levels/functions. The management review meetings are recorded & actions
initiated by concerned persons.
QUALITY MANUAL
CUSTOMER NEED
MANAGEMENT RESPONSIBILITY
RESOURCE MANAGEMENT
PRODUCT REALIZATION
MEASUREMENT ANALYSIS & IMPROVEMENT
CUSTOMER SATISFACTION
CONTINUAL IMPROVEMENT OF THE QUALITY MANAGEMENT SYSTEM
PRODUCT
HUMAN RESOURCE DEPARTMENT:
The organization employs personnel who are competent judged on the
basis of appropriate education, skills & experience in performing affecting
product quality.
Competence, Awareness, Training:
Organization provides training to fill the gap in knowledge/skills & evaluate
effectiveness of such training. It arranges to induct knowledge across the board
to all levels of employees, the importance of their activity & its contribution to
enhancement of quality of the product/process.
The organization maintains the records of training imparted
including imparted skills, experience, competence etc.
Infrastructure & Work Environment:
The organization have assessed and provide necessary infrastructure for
working to ensure conformity of product. These include equipment/machinery,
work environment, safety requirement as applicable, support services such as
transport, communication equipment etc.
Manufacturing process of SINGLE YARN
SAFETY MEASURES IN THE INDUSTRY
COTTON OPENING
MIXING
BLOW ROOM
CARDING
SLIVER LAP
RIBBON LAP
COMBER
DRAWING
SIMPLEX
RING SPINNING
AUTO CONER
PACKING
DELIVERY
PRECOMB MIXING
SUPER LAP
MIXING
BLOW ROOM WITH BLENDOMAT
CARDING WITH CHUTE FEED
In GTN industries safety is the major concern in every part of the
work .The industry also implemented the safety precautions in every
department .
Providing safety equipment for the workers in different sections for their
health safety.
In the industry there is a fire preventing alarm and fire preventing water
facility is also provided.
For every machine a board is attached which guides how to work on the
machine, to protect themselves from the hazards.
Management also giving awareness to the workers through the fire
preventing boards, and writing boards.
Every department is provided with a first aid box.
WASTE RE-USE:
In GTN industries the waste occurred is 28%, utilization is 70%, invisible loss is
2%. In the industry different approaches are defined for treating the waste. The
waste collected from different sections like BLOW ROOM, CARDING,
COMBING, SIMPLEX, RIBBON LAP, SLIVER LAP etc are contaminated in the
wasting section.
There are 9 types of waste collected which are as follows
1. Gutter
2. Cylinder Fly
3. SWP(sweeping) waste
4. Dropping no.
5. Hard waste or Yarn waste
6. Comber noil
7. Flat strips
8. Licker in fly
9. Roving ends
The collected waste from different sections is packed by using WASTE BALE
PACKING MACHINE.
WASTE RE-USE:
For the utilization of waste there are two types of waste are classified
SALABLE Waste
USABLE Waste
SALABLE Waste: The waste which is not used for the production is called
SALABLE waste. This waste is sell to the local manufacturers for different
purposes.
Example:
COMBER waste is used for surgical cotton
FLAT STRIPS is used for bedding
HARD WASTE is used for cleaning purpose, automobile cleaning
USABLE Waste: The waste which is suitable for the production purpose is called USABLE waste.
YARN Testing:
Electronic Wrap ReelBrand: STATEX
Test Procedure::
Reels up to 10 yarn skeins
Number of revolutions can be preselected from 1 to 200 by the operator
through keyboard with LED display
The reel starts gently and smoothly to increase normal speed under
microprocessor control, before reaching the preselected measuring length,
it slows down and approach the end of the measurement slowly and stops
at accurate position, which ensures uniform winding without any stretch
Stainless steel reel for accurate length measurement and better stability
Separate yarn stand is provided to accommodate 10 cops
MODEL E1.5/10C E1.5Y/20C E1M/10C E1M/20C
Reel
circumference 1.5 YARDS 1.5 YARDS 1 METRE 1 METRE
No. of skein
yarns 10 20 10 20
It is designed for adjustable pre-tension mechanism facilitates tension as
per ASTM standard to suit individual yarn through common selector. This
advanced pretension mechanism ensures uniform tension throughout
winding
ORGANOGRAM
VCMD
CE-Hyd
VP(P) VP(w)&MR
MGR(Prog AGM(c)
DM(P)-RD
SR.M(OA) DM(P)
M (PRD)
DGM(P&IR) SR.GM(RM&SP)P)P
GM(IT) SR.M (E)
Civil Supervisor
JR.off store
SUPER
JOBBER
HELPER
OPERATOR
DMM
Foreman
Sup.MT
FITTER
Asst.FITTER
HELPER
SUPR (PKG)
DM (OA)
AM (QA)
QA (Asst)
SUPERVISORS
MAISTRY
OPERATORS
OFF (RM)
ASST
AM(IT)
ASST
AMEEE
Foreman
Electrician
MT.Personnel
MRKT office SGM (M) DGM(M) DM(M)
OFF logistic
Personnel Asst M(C) Cashier
Mgr.Pers
SR.SUP
DM (P)
SECU
TKP
STENO
RECPT
FIBER TESTING:
USTER HVI SPECTRUM:Brand: USTER
PROCEDURE:
In this instrument except Trash and Neps all the parameters are checked.
For the measure of micronaire study 10gm sample is collected for the
testing.
The USTER HVI SPECTRUM provides with the required information of
Standard measurements of fiber length, uniformity, strength, micronaire,
color and trash to assist in selecting the right cotton for end product
Growers, ginners, traders and spinners specify, evaluate and select cotton
according to the quality standards of USTER HVI – the
only accepted standard worldwide.
The USTER HVI SPECTRUM is the only HVI instrument that is
Equipped with a patented moisture probe. Knowing the moisture
Content of the cotton at the time of testing.
The USTER BALE MANAGER is software provides information about the
cotton quality, allows customization for the bale selection process, and
stores historic information on laydowns that have already been consumed.
YARN Testing:
USTER TENSORAPID:
The USTER TENSORAPID gives all the known measured values in
tensile testing and offers improved analysis of the yarn quality. The results
determine the tested yarn’s suitability for knitting or weaving.
The software package with USTER TENSORAPID calculate the following
additional characteristics:
• Elasticity-tension behavior of yarns
• Yield point definition by either strength or stretch
• Retardation and relaxation tests
A range of specially designed clamps and accessories guarantees
optimal, reliable and reproducible testing of yarns, hanks, slivers and also
fabric strips.
The clamps can be arranged horizontally or vertically, depending on the
material being tested. With a horizontal clamping position, the danger of
clamp breaks with critical yarns can be avoided, since a considerable
percentage of the stress will be absorbed by the frictional surface.
Electronic Twist Tester:
Brand: STATEX
Electronic Twist Tester is used to test single yarn and double yarn. Specimen
length adjustable from 0 to 20 inch or 0 to 50 cms.
Procedure:
Provision to test S and Z twist
Results are displayed in TPI and TPM. Minimum number of control
switches for complete use
It is used to test heavy yarns and Multi twisted yarns
Scale provided to measure elongation of test results
Automatic counter start/stop using optical sensor
Pre-tension weight available up to 250 grams
Suitable for both Microprocessor Twist Tester and Electronic Twist Tester
QUALITY ASURANCE Department
In the quality assurance department testing of the fibers, hanks, and yarns is
done for the end product quality .It includes three stages they are,
1. Incoming inspection
2. Process control inspection
3. Final inspection
1. INCOMING INSPECTION: Incoming inspection includes the raw
materials, stores, materials, i.e. incoming goods are inspected thoroughly so, that
no faults can’t be occurred in the product with the raw material or with machine
etc.
2. PROCESS CONTROL: DEM Process approach is used in the GTN industries
DEM cycle approach
3.
FINAL INSPECTION: Final inspection include the testing of hank ,fiber and
yarn .every processing element like carding ,combing, simplex etc.is undergoes
into checking whether it is acquired quality according to the specification . Fibers,
hanks, yarns are tested by using different Instruments. The results of the testing
instruments used by GTN industries are accepted by worldwide.
Environment for Q&A Dept.:
650– RH (relative humidity) - -2250 - TEMP - ±2
In the quality assurance department the parameters of yarn checked Are as follows
COUNT
STRENGTH
CSP (Count Strength product)
ELONGATION
CMT ( classimate faults in yarn)
CV (count variation)
PLAN ACT
DOCHECK
IMPERFECTION
I. Thin Places 2. Thick places 3. Neps
There are three types tests taken in the Q&A Dept
Fiber testing
Yarn testing
USTER CLASSIMAT QUANTUM:
PROCEDURE:
By using USTER CLASSIMAT QUANTUM We can check cleared
and uncleared yarn, providing perfect classification of thick and thin
places, as well as checking infrequently occurring yarn defects and,
recently, foreign fibers in the yarn.
Classifying foreign fibers into 27 classes according to
the FOREIGNCLASS classification system which is recognized worldwide.
USTER CLASSIMAT QUANTUM allows the distinction to be made
between organic and non-organic foreign matter
Defining customized classes allows targeted monitoring of individual faults
in the desired size, for thick and thin places as well as for foreign fibers.
Determining infrequently occurring yarn faults in 23 classes of thick and 4
classes of thin places.
USTER STATISTICS Compare measuring results with the international
quality benchmarks directly on the screen.
BALANCES&WEIGHING SCALES:
Brand: AFCOSET
PROCEDURE:
Afcoset balances are peerless in accuracy and reliability.
Selectable weighing modes Kg, counting or percentage.
Large and easy read out display mounted on tall column
Outstanding Accuracy up to 1/10000 displayed count resolution.
Optional RS232 allows connection to computer.
PACKAGING Section:
In the packaging section cones which are wounded on auto coner are
taken for packaging.
Every cone will be checked under UV lamp, if any fault found it is removed
again rewounded.
Faults include oil marks, waste attached, and mixing of different counts in
the yarn.
12 cones are packaged in one box. Cones are first packed with polybag
and next in the gunny bag and put in the company logo box.
Every box consists of following information
ORDER NO. , COMPANY, COUNT, LOT NO. , COUNTRY
ORDER NO.: It is order no of the buyer given by the company GTN.
COMPANY: To the company whom they are manufacturing for
COUNT: Count of the cone
LOT NO.: It is lot no. in which the yarn is manufactured