INTRODUCTION TO TEXTILE INDUSTRY Everyone in the world knows Pakistan as an agricultural country. Among all others, cotton is the major crop. This cotton, after processing takes various forms including yarn, fabric and other textile related products. The industry that is engaged in this area is much diversified in nature. There was a need of central platform that can assure a liaison between all the sectors of this industry. To cater the same need, All Pakistan Textile Mills Association (APTMA) was established in 1959. It was an untiring effort of its founders that resulted in a success and APTMA became a real representative of the whole textile sector of the country. Presently there are 419 registered members comprising of 322 spinni ng units ,44 weaving units and 53 compos ite units. APTMA is the most important and res our cef ul association of the coun try. The texti le indust ry cont rib utes ove r 60 percent to Pakistan's exports, over 38 percent to employment and over 20 percent to value added production by manufacturing. Textile industry is the most important industry of Pakistan. It contributed 64% ($ 6.85 Billion approximate) of the total exports of Pakistan in 2003. It employed 38 % of the total employed population of Pakistan. Textiles industry contributed almost 10.50 to total Gross Domestic Product of Pakistan. 31% of the total investment relate of the textiles industry. Government earns Rs.1.1 Billion form textiles industry in shape of taxes. Knitting industry is one of the most growing industries in Pakistan. Knitwear’s are exported to all parts of the world. USA is the largest buyer of knitwear’s from Pakistan. India, Bangladesh, and some other countries are competitors of Pakistan in this industry. But Knitwear exports of our country are increasing day by day. In 1996 exports ofknitwear were 50% more than 1990, which shows a growing sign of the industry. Companies like Levi’s, Nike, Target, Dockers’s etc., are the major buyers of knitwear. Now why they are buying from third world countries the reason is that here it cost them less and they get the same quality. Thus if the cost factor can be controlled and quality can be maintained in the coming years, we can increase our knitwear exports several times and it can help to reduce our trade deficit. But Government should also help to increase exports.
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Everyone in the world knows Pakistan as an agricultural country. Among all others,
cotton is the major crop. This cotton, after processing takes various forms including yarn,fabric and other textile related products. The industry that is engaged in this area is much
diversified in nature. There was a need of central platform that can assure a liaison
between all the sectors of this industry. To cater the same need, All Pakistan Textile Mills
Association (APTMA) was established in 1959. It was an untiring effort of its founders
that resulted in a success and APTMA became a real representative of the whole textile
sector of the country. Presently there are 419 registered members comprising of 322
spinning units,44 weaving units and 53 composite units. APTMA is the most important
and resourceful association of the country. The textile industry contributes over 60
percent to Pakistan's exports, over 38 percent to employment and over 20 percent to value
added production by manufacturing.
Textile industry is the most important industry of Pakistan. It contributed 64% ($ 6.85
Billion approximate) of the total exports of Pakistan in 2003. It employed 38 % of the
total employed population of Pakistan. Textiles industry contributed almost 10.50 to total
Gross Domestic Product of Pakistan. 31% of the total investment relate of the textiles
industry. Government earns Rs.1.1 Billion form textiles industry in shape of taxes.
Knitting industry is one of the most growing industries in Pakistan. Knitwear’s are
exported to all parts of the world. USA is the largest buyer of knitwear’s from Pakistan.
India, Bangladesh, and some other countries are competitors of Pakistan in this industry.
But Knitwear exports of our country are increasing day by day. In 1996 exports of
knitwear were 50% more than 1990, which shows a growing sign of the industry.
Companies like Levi’s, Nike, Target, Dockers’s etc., are the major buyers of knitwear.
Now why they are buying from third world countries the reason is that here it cost them
less and they get the same quality. Thus if the cost factor can be controlled and quality
can be maintained in the coming years, we can increase our knitwear exports several
times and it can help to reduce our trade deficit. But Government should also help to
CH. Nazir Ahamad established the Masood textile mills limited in 1984 after them now
Ch. Shahid nazir is the chief executive of Masood textile mills limited. The Masood
textile mill is established under the company ordinance 1984. The Masood textile Mills
is listed in KSE in 1999.
The company has latest equipment and machinery to serve globally. Masood Textile
Mills is the only textile mill in Pakistan with latest computerized Barcode System that
assures quality in every operation of production from spinning to packing.
The company has modern computerized networking system. All the Accounting and
finance relating work is carried out through computers. The company has capability infabric dyeing; ginning, spinning, knitting, laundry and apparel Manufacturing. The
Company's apparel division is producing high quality garments.
Main products of Masood are Yarn, Fabric, and garments.
They are leaders in creating, developing and manufacturing of knitted apparel products
right from basic to highly fashioned garments thus responding to emerging trends in the
industry. Some of its customers are Eagle, Hanes, Polo Jeans, JC Penny, and Champion.
The company implemented the quality system and had awarded ISO 9002 certificate.
Masood has the technology with expertise, products with knowledge and most
importantly the right mindset to achieve total customer satisfaction. The company adopts
standardized tests for quality assurance purpose. The company is exporting its products
Masood Textile Mills Limited was established in 1984 by Chaudary Nazir Ahmed. This
is located 32 km Sheikupura road Faisalabad with its apparel Division located in center of city producing quality garments. MTM is working from 1995 with 75 sewing machines.
In 1996 company management has made the plan to use his own production of yarn for
producing value added products because of the slump in international and local yarn
market. For implementation this plan company made heavy investment in 1997 for
modernization and expansion of production facilities towards value added operations. For
this purpose 6 dyeing machines were installed and further knitting dyeing and finishing
machinery was being imported. Building was also constructed to install more stitching
machines for producing value added products now in 2010 company has more than 1725
sewing machines. In 1998 company was earning 470 million rupees per annum which
was increasing day by day. In 2009 it increases and earning raise to 6120 million rupees
per annum. In starting they were using manual recording system of inventory, induction,
raw material, salaries and vice versa. Now MTM is the only textile in the Pakistan with
latest computerized bar code system, which assures quality in every operation from
spinning to packing; products of each dept carry bar coded stickers which bear all the
details and history of the operation of that product. Hence if any problem accurse one
can trace back the root of the problem and enables to prevent the root cause of the
problems in future. Besides this, Masood is one of the few textile mills of Pakistan which
has in house Ginning, Spinning, Knitting, Fabric, Dyeing, Processing, Laundry and
It is the second responsibility of PPC to check the production capacities of Masood. Here
by production capacity we mean two things firstly Capability. It means that the labor and
machines at Masood are able or not to prepare the garment that customer requires.
Secondly On Time Delivery. It means that we will handover the shipment as per
contract. For this purpose PPC has to check these things: Fabric Production Capacity,
Cutting and Stitch time, Vacant Labor and Machines for Processing the Order
PPC has to provide these information's to the merchandiser so that he can negotiate with
customer.
3. Production Allocation
PPC fulfill this responsibility by making a schedule, which deals with when and from
where fabric is received, when cutting is done, to which production unit order will be
process, and so on.
4. Monitoring According to Time Line & Control
All the processes being carried out are monitored according to preplanned timeline.Masood's AMS help PPC to monitor all the processes. in order to meet any uncertain
situation safety margins are kept. PPC not only monitor all the processes but also control
the pace of process in order to send shipment on time.
5. Re-Planning
If any uncertain situation occurs, it is responsibility of PPC to re-plan in such a manner
that it doesn’t affect the shipment schedule. These uncertainty may arise due to fabricshortage, fault in any main machine etc.
In MTM marketing departments is very active. As MTM is a marketing oriented
company so this department has to play a vital role in company. Basic objective of merchandising department is to take orders from existing customers and to attract new
customers. And to satisfy the customers by quality products and timely deliveries.
Working
Following works are performed by this department
.merchandising department by dividing it into seven steps, which are as follows:
1. Handling Inquiry.
2. Product Development Package.
3. Price Negotiation.
4. Sampling.
5. Fabric Development.
6. Pre Production Approvals.
7. Bulk Production Monitoring and Follow up.
1. Handling Inquiry
There are basically two types of customers, one are new, and others belong to portfolio of
existing customers. It is the duty of merchandising department to tell the new customers
what Masood is capable of and what it is producing.
After receiving the product package development Merchandiser prepares the proto
sample. These samples may be send in any fabric and sends it to customer for approval.
Lead-time of proto sample is 3 to 4 days. After proto type sample They sent the “Color
Stack Sample”. This sample shows department understanding about the fabric. This
sample includes all the required color. When prospective customer really takes interest in
our product then he demands “ADAR (Apparel Design for Apparel Review) Sample”.
These samples are kept as reference and use to compare it with final products. At this
stage order is considered to be achieved but “Order Confirmation Sheet” is received from
customer after we response positively to volume of production and the time frame given
by customer in “Bi-Sheet”. After receiving order confirmation sheet, we start our preparation to produce in bulk quantity. PPC has prepared a complete time schedule of all
activities
5. Fabric Development
When merchandising department receive product package development it will send S/O
(Sample Order) to mills. If the required fabric is not available in the fabric library then
Research & Development Department of mills start working on that fabric. If it is presentin fabric library then the dates on which required machines are available, production
starts.
6. Pre Production Approvals
Pre-Production samples sent to the customers for “RTL Testing”. This sample reflects the
true picture of bulk production. When these samples are approved from customer then
they start production at full scale.
7. Bulk Production and Follow up
The responsibility of merchandiser doesn’t end at this stage; he has to continuously
follow the process. Some time customer’s representative checks production to assure that
As it is evident from the name, purchase orders which are ready to be shipped, are storehere. In Masood, when production of order is completed then it is packed in boxes and
barcodes are pasted on them. These barcodes contain all necessary information regarding
the contents of boxes. Final quality check of the shipment is done here. On the day of
shipment the boxes are loaded on trucks and final entries are stored in computer.
The main objective of the quality assurance departments is to ensure the quality of
finished products according to the customer’s specification.
Role of Quality Assurance
Quality assurance department’s first responsibility is to check the quality of finished
products. For this purpose quality audit is conducted. In which the finished garments are
checked according to customers P.O. Fabric. Quality, Color, Sizes, Accessories,
Embroidery, Stitching Quality every thing is checked by Quality Assurance Department.
If every thing is OK then the shipment is approval otherwise it is rejected. Because
quality policy of MTM is to satisfy customer at every cost.
While auditing finished goods Q.A Officer also checks the measurements of the garments
and tallies them with standard measurements for the respective sizes. In final inspection
the officer have a standard fault form. He checks the garment and fined faults. If the fault
ratio is more then 2.5% he rejected the piece.
In that form description of faults are mentioned. Q.A department ensures that 100 %
quality is maintained. Beside quality audit Quality Assurance department evaluate the performance for the In-line inspectors and final inspectors. On these evaluations their
pays and bonuses are allocated. The department also gives cash awards to best
performers. And a quality trophy is also given to best unit.
The HR department does the recruitment. Recruitment is done basically for two classes.
Class S is for labors and supervisory level while class M is for Management. For
recruitment in both classes Job Analysis is done that where new vacancies can be
arranged or where there occurs a vacancy for a job and what kind of qualified person is
required for the job. Human Resource Department does Strategic Planning for new jobs
in Masood. Jobs are normally announced after every six months. Selection is done in two
ways. Number one is that Internal Sourcing is done according to the capability and
performance of worker. External recruitment is done for the officers. For recruiting
officers they take test and interview, and the succeed ones are appointed as Management
Trainees. After a period of three months they are again evaluated the persons who
qualified become the permanent members of Masood’s Team. The workers are hired on
trial. If there work is satisfactory then they are selected.
HR department also keep the personnel record either the worker is a contractual or
permanent worker. A profile of every worker is maintained in the computer based
Human Resource Management System (HRMS).
2. Training and Development
Although it is the function of Human Resource Department but in Masood they haverecently establish a separate Training & Development Department. The responsibility of
this department is to train new employees and to develop a clear career path for the
employees. This department also arranges training for employees who are promoted to next
level. After providing complete training the work of this department doesn’t end. They take
feed back to evaluate the results of training.
3. Compensation and Benefits
The HR department carries out wage surveys. HR department checks pay and other legal
benefits and benefits like overtime, bonus, leave encashment, gratuity, subsidized mess
Division) which is 32 Km far from it. All computers of Apparel Division are linked to
Fabric Division through a communication Tower. This system works like mobile phone
system. Beside that MTM has its on ISP (Internet Service Providing facility). It hassatellite Internet system. For this a satellite dish is installed at the factory. Every
It includes the material whichis used in production, as a minor part of the garments it
includes:
• Buttons
• Labels
• V.M.T. -----> vender mark ticket
• Plastic pins
• Silver hand pins
These sundries are imported time by time and according to the demand forwarded bymerchandiser. Usually the suppliers are nominated by the foreign buyers. So the import
department forwards a purchase order about its required product. Then the suppliers send
the Performa invoices in which prices are shown. Terms and conditions of transactions
are set. The suppliers also seek for the approval of the Performa invoice. Then the import
I worked in PPC department (Production Planning & control) the manager of PPC
delivers a very important and interesting lecture. He not only delivers the lecture but also
takes presentation individually and offers to all to come and sit with him for consultation
of further detail. I got this opportunity and saw him many time to complete our report
and for solving question which aroused in my mind.
First day Asst. Manager gave briefing about the department. He told me that the primaryresponsibility of this department is to manage and run the production in an efficient and
effective manner. To forward accurate and timely information to relevant departments is
the objective of this department He explained the functions and procedure of this
department. According to his statement, PPC department performs these functions like.
• MRP (Material requirement planning)
•
CRP (Capacity Resource Planning)
When an order is confirmed Merchandising forwards complete details about the style to
PPC. I learned that how the plans are made for material required and how they monitored
the consumption of material. A material required is further divided into Store Plan, and
Cutting Plan. I got information about the production scheduling. Manager explained that
at second stage, plans about the production scheduling are prepared. Date shipment,
capacity of the unit and worker capacity are the factors, which they have to consider in
production scheduling. I also learned how reports are prepared and forwarded to different
During my stay in MRP, I came to know that “Assurance of the availability of rightquality material at competitive cost for the timely production” is the objective of this
department. I also came to know that MRP works in collaboration with Imports,
Purchase and Store departments. Manager named MRP is the mother department and all
above-mentioned departments are working under its control. I got information about the
planning for procurement. I saw that how the planning is taken place of each category of
direct material and indirect material. Manager told me about the procedure of
procurement. I came to know that quality of the yarn, production capacity; history and
lead-time are the major considerations for yarn procurement. I got some knowledge about
sundries (sundries are special type of material which includes buttons, zips, labels, tapes
etc) and their process of imports. I came to know that to keep different, items in stock
that are used in the production process or anywhere else in the factory is the main
function of the store.
CRP (Capacity Resource Planning)
It is the second responsibility of PPC to check the production capacities of Masood. Here
by production capacity we mean two things
Capability
It means that the labor and machines at Masood are able or not to prepare the garment
According to the schedule the next department which I join that is the Quality control
department and in that department I met with the Deputy Manager Mr. Irfan and he told
the quality about the MTM.
How does Masood maintain Quality?
Masood Textile has documented a quality manual that states the quality management
system of the organization. Management establishes a documented quality plan setting
out the specific quality practice, resources required and the sequence of activities relevant
to particular product.
Quality Control System at Masood
There are quality checks at every stage of manufacturing starting from Raw Cotton, Yarn
Fabric, Processing, Cutting, and Stitching & Packing.
Before the fabric is cut, it is checked whether it conforms to the customer’s standards of
shrinkage, finished g/cm 2 etc. After each lot of fabric is cut, 100% cut parts inspection
is conducted to ensure that only good quality pieces move to the stitching units.During the process of sewing, each and every process is inspected by in line inspectors.
The inspectors make sure that only good parts move to the next stage. An individual
tracking number is sewn inside each garment. After trimming and pressing of the
garments, each garment is inspected by highly experienced final inspectors. The Quality
assurance team monitors the performance of every individual inspector b picking up the
inspected garments and checking the quality of these garments.
To ensure that the garments are packed as per the requirements of valued customers, they
can even track & check, which ease the garments, has been packed in. With the help of
Masood has a very strong corrective and preventative action plan. Masood hascentralized the corrective action and controls the non-conformity arising in the system. If
necessary the relevant person immediately takes the corrective action. For preventative
action, the record is kept by the department head. Electronic records are kept by the
Information Technology Department.
ISO & TQM
Masood has ISO 9002 certification and the registration # 99086699. We have the logo of
three accreditation bodies ANSI RAB USA, UKS UK. DAR/TAG Germany and the
audits were conducted by MOODY.
ISO department provides a management system at Masood, which is free of non-
conformance. The department has training system that creates awareness of Total Quality
Management System (TQM). All the departments and people at all involved in this
program. Masood has a team of qualified and certified auditor who would check,
The staff is not properly motivated due to lake of incentives and less wages offered by the
company.
Less promotional activities
The company has very less promotional activities in local an international media.
Opportunities
Domestic market
They are not selling their products locally they have an opportunity to capture the local
market.
Capturing the new market
The company has very vast opportunities not only in Pakistan but also in foreign
countries of capturing the market. The company has the opportunity to capture the
markets of Saudi Arabia, Dubai, Qatar, Oman and other European countries.
Acquisition of modern technology:
The company at the current is using technology from Italy, Japan and Germany, but the
company has the opportunity to acquire the modern technology from China which is costeffective and has efficient and effective performance, similarly modern technology from
India can also be obtained
Expanding Product Line:
They can increase their production in sense of increase their product line if they will