A S TUDY O N AMTEK I ND US TRI ES PVT LTD 1 | P a g e CMR CENTER FOR BUSINESS STUDIES EXECUTIVE SUMMARY INTRODUCTION Today’s world need is a corporate world and it requires a lot of management activities to achieve success, for this purpose in this competing corporate world of multinationals and industries , industrial revolution has brought with it group production and group consumption activities and also it has brought in a lot of corporations competing forpreferences and success in the business world, it may be a manufacturing industry orany other type of industry experience and specialization, have become a must to compete with others become very much essential for all the companies. Lecturers teach the students; this learning will make an individual knowledgeable in theory of the various functions of a company. But a person comes out from class room and visits various industries, in this situation he can learn more from them. In such a situation real experience in the practical functioning and operations of a company can be of very much use to the students of management studies. For the purpose of acquiring practical knowledge of the working and functioning of a company. Bangalore University has incorporated an in plant training into its business management schedule. This in plant training tells us how the different departments in the organization work as a single unit. REASEARCH METHODOLOGY OBJECTIVES OF THE STUDY:To Study the organizational structure. To analyze the benefits of setting up the industry. To know the marketing mix to promote sales. To study the production and finishing process of the Industry. To fulfill the requirement of University by submitting the report based on study. SCOPE OF THE STUDY: The study has been conducted to become familiar and to have a look with the various aspects of large scale industry. Hence this study would be very much helpful for any new entrepreneur as well as the student of the concerned subject. As a part of my studies in MBA, this organizational studies were has given me a chance to enrich my knowledge and talent. It has given me an opportunity for a practical exposure of how a business is run.
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Today’s world need is a corporate world and it requires a lot of management activities
to achieve success, for this purpose in this competing corporate world of multinationals
and industries , industrial revolution has brought with it group production and group
consumption activities and also it has brought in a lot of corporations competing for
preferences and success in the business world, it may be a manufacturing industry or
any other type of industry experience and specialization, have become a must to
compete with others become very much essential for all the companies. Lecturers teach
the students; this learning will make an individual knowledgeable in theory of the
various functions of a company. But a person comes out from class room and visits
various industries, in this situation he can learn more from them. In such a situation realexperience in the practical functioning and operations of a company can be of very
much use to the students of management studies. For the purpose of acquiring practical
knowledge of the working and functioning of a company. Bangalore University has
incorporated an in plant training into its business management schedule. This in plant
training tells us how the different departments in the organization work as a single unit.
REASEARCH METHODOLOGY
OBJECTIVES OF THE STUDY:
To Study the organizational structure.
To analyze the benefits of setting up the industry.
To know the marketing mix to promote sales.
To study the production and finishing process of the Industry.
To fulfill the requirement of University by submitting the report based on study.
SCOPE OF THE STUDY:
The study has been conducted to become familiar and to have a look with the various
aspects of large scale industry.
Hence this study would be very much helpful for any new entrepreneur as well as the
student of the concerned subject. As a part of my studies in MBA, this organizational
studies were has given me a chance to enrich my knowledge and talent. It has given mean opportunity for a practical exposure of how a business is run.
Factory layout means the positioning of the departments in the factory. Storage
points in the working area, including office and staff facilities relative to one another.
The designing of a good factory layout calls for an expert knowledge.
The layout of AMTEK INDUDTRIES PVT LTD is well designed andeffectively planned. The location selected for setting up the plant is best suited for
carrying out the production activities. The size, shape and topography of the site are
favourable for the firm.
MACHINE LAYOUT:
Machine Layout is a plan or the act of setting the machines in an orderly
manner so as to obtain its optimum utilization and to avoid unnecessary delays and
wastages in production. The Layout of machinery is of major importance as it affects
the flow of materials and various processes. A systematic arrangement of machinery
increases the speed of the production process, prevents wastage of time, money, effort
and it saves floor space there by reducing investment in plant and increasing the
efficiency of the operators.
The firm has set up a well planned machine layout within the factory building
which suits the factory layout as well as the production procedure of the firm. The type
of machine layout setup by the firm is STRAIGHT – LINE method of machine layout.
Under the STRAIGHT – LINE method of machine layout, the firm has arranged
the machines in a straight line in the sequence of its operations. These machines are
installed as near as possible to each other because the output of one machine becomes
the input of other machine. The materials and semi-finished products move in a pre-
determined channel of operation, this involving a lesser manufacturing cycle time.
This layout permits the forward flow of materials from the raw materials stage to thefabrication stage, then to the finishing stage and finally to the coupling section of the
pipes. The following diagram clearly explains the machine layout of the firm.
THIS TYPE OF MACHINE LAYOUT HAS PROVIDED THE FIRM
WITH CERTAIN ADVANTAGES SUCH AS:
1. The firm is in a position to effectively utilize the available space owing to better
and systematic arrangement of machines.
2. Under this type of machine layout, the route travelled by the material is short.
Hence the use of mechanical handling equipments enables the minimizing of
the material handling cost.
3. Since production is continuous and uninterrupted, work-in-progress is always
kept at the minimum.
4. There is no back-tracking or deviation of processes from the schedule path and
time.
5. This layout ensures effective production control and better inspection.
6. Semi-skilled labour can be used to operate in this type of machine layout.
A PART FROM THESE ADVANTAGES, THE FIRM FEARS
FROM CERTAIN DISADVANTAGES FROM THIS TYPE OF
MACHINE LAYOUT SUCH AS:
1. Any break down in one of the machines leads to the stoppage of the production process because the operations of succeeding machines are dependent on the
preceding machines.
2. This type of machine layout generally lacks flexibility in adjustments.
Hence, straight line type of machine layout is suitable for repetitive processes
employed to manufacture a large volume of standard products.
In canvas work threads are stitched through a fabric mesh to create a dense pattern that
completely covers the foundation fabric. Traditional canvas work such as bargellois a
counted-thread technique.[6] Since the 19th century, printed and hand painted canvases
where the painted or printed image serves as colour-guide have eliminated the need for
counting threads. These are particularly suited to pictorial rather than geometric designs
deriving from the Berlin wool work craze of the early 19th century.
In drawn thread work and cutwork, the foundation fabric is deformed or cut away to
create holes that are then embellished with embroidery, often with thread in the samecolour as the foundation fabric. These techniques are the progenitors of needle lace.
When created in white thread on white linen or cotton, this work is collectively referred
Free motion machine embroidery involves simultaneously running the machine and
skilfully moving tightly hooped fabric under the needle in unison with the machine to
create even stitches.
The operator thus builds up and sews out the embroidered design "manually", with
either normal "running" stitching (running stitch) and/or with any fancy built-in stitch
types (supported by this sewing machine) to artfully create "an image" composed of
stitching sewn into a piece of fabric or other similar item.
Producing many parallel rows of straight stitching is an effect that can be employed to
fill in an area with a solid looking fill effect or using a machine's inbuilt zigzag stitch(most have one) can be used to depict thicker lines in a design or for bordering and
appliqué applications.
This process would obviously involve stopping and "re-threading" the machine
manually for each subsequent colour in a multi-colour design (as sewing machines
generally only have one needle) and also manually trimming out and cleaning up loose
or connecting threads with a pair of clippers or small scissors after the design is
completed.
Also it goes without saying that anything that you create in this way would be a "one
off" as it is being done very manually and has not been store digitally (as an
embroidery file) or sewn out automatically and thus is not readily able to be easily or
exactly reproduced.
With the advent of computerized machine embroidery, the main use of manual
machine embroidery is in fiber art and quilting projects. While some still use
this type of embroidery to embellish garment, with the ease and decreasing cost
of computerized embroidery machine, it is rapidly falling out of favor. Many
quilters and fabric artists now use a free machine embroidery process often
called "thread drawing" (or thread painting) to create embellishments on items,
These days virtually all modern embroidery machines are computer controlled and
specifically engineered for embroidery. Industrial/commercial embroidery machines
and sewing/embroidery machines both have a hooping or framing system that holds the
framed area of fabric toughly and securely underneath the sewing needle and move it
around automatically to create a design from a digital embroidery file (pre-made
pattern) Both can read and sew out embroidery design files (of various types) with
varying degrees of user input required depending on its capabilities.
For example sewing-embroidery machines generally only having one needle willrequire the user to change thread colours "on the fly" where as a multi-needle
(industrial) machine having more needles can generally be threaded up all at once prior
to running the design. This method also requires the user to input the correct colour
(needle) change sequence into the machine beforehand.
Modern (industrial) embroidery machines can trim and change colours automatically
and can have anywhere up to 15 or more needles per "head"(available colours).
The term "head" refers to the "sewing head" as some of the larger industrial embroidery
machines can sew the same design out onto 20 (or more) garments at once (as any one
of these industrial machines can have many sewing heads).
Machine formats: Specific to a particular brand of embroidery
machine. (I.E the files available for use with particular embroidery
machines which are not so easily edited or scaled.)
Generally every different embroidery machine manufacturer (brand of machine) has
one or more specific embroidery "machine formats" specifically designed to service
this particular brand.
However even although generally "Machine Formats" where originally designed to
service only their own specific machine brand, some formats such as Tajima's ".dst",
Melco's ".exp"/".cnd" and Barudan's ".fdr" have become so prevalent that they have become ad-hoc standards in themselves and are often even supported by machines built
by companies actually in competition with the companies/machines that these
represent.
These "Machine formats" generally contain primarily stitch data (offsets) and machine
functions (trims, jumps ETC) and are thus not easily scaled (with-out affecting the
stitch density) or edited (without laborious manual stitch by stitch editing).
Many embroidery designs (in various popular machine formats) can be downloaded
from web sites on the net and one can be sewing them out within minutes. Please note
however that there are many different brands of machines, and each may use a different
format. So when purchasing or downloading free designs it makes allot of sense to
ensure you get the right format for your machine. If your format is not available,
conversion programs are available to convert from one machine format file to another
(i.e. from .PES to .HUS or from .DST to .PCS, for example) however it should be notedthat the results from many of these conversion programs (and even from some of the
more reputable digitizing packages) are unreliable.
A person who creates a design is known as an "embroidery digitizer" or "puncher". The
digitizer, or puncher, users digitizing software to create their embroidery design. The
digitizer creates the design in the native file format for the digitizing software. These
are 'Object Based' design and allow the digitizer to easily reshape and edit the design
The native file formats retain important information such as:
Object outlines
Thread colors
Original artwork used to punch the designs
As a digitizer it is critical to maintain and keep the original digitized design file.
Converting the design to a stitch file such as .DST, .PES and .DSB will lose many of
the valuable information, and make editing and changing the design very difficult or
impossible.
Software vendors often advertise "auto-punching" or "auto-digitizing" capabilities.
However, if high quality embroidery is essential, then industry experts highly
recommend either purchasing solid designs from reputable digitizers or obtaining
training on solid digitization techniques.
Editing designs:
Once a design has been digitized, it can be edited or combined with other designs bysoftware. With most embroidery software the user can rotate, scale, move, stretch,
distort, split, crop, or duplicate the design in an endless pattern. Most software allows
the user to add text quickly and easily. Often the colors of the design can be changed,
made monochrome, or re-sorted. More sophisticated packages will allow the user to
edit, add or remove individual stitches. For those without editing software, some
embroidery machines have rudimentary design editing features built in.
Loading the design:
After editing the final design, the design file is loaded into the embroidery machine.
Different machines expect different files formats. The most common home design
format is PES. Common design file formats for the home and hobby market include:
ART, PES, VIP, JEF, SEW, and HUS. Embroidery patterns can be transferred to the
computerized embroidery machines in a variety of ways, either through cables, CDs,
floppy disks, USB interfaces, or special cards that resemble flash and compact cards.
To prevent wrinkles and other problems, the fabric must be stabilized. The method of
stabilizing depends to a large degree on the type of machine, the fabric type, and the
design density. For example, knits and large designs typically require firm stabilization.
There are many methods for stabilizing fabric, but most often one or more additional
pieces of material called "stabilizers" or "interfacing" is added beneath and/or on top of
the fabric. Many types of stabilizers exist, including cut-away, tear-away, vinyl, nylon,
water-soluble, heat-n-gone, adhesive, open mesh, and combinations of these.
For smaller embroidered items, the item to be embroidered is hoped, and the hoop isattached to the machine. There is a mechanism on the machine (usually called an arm)
that then moves the hoop under the needle.
For large commercially embroidered items, a bolt of fabric can be worked by a long
row of embroidery "heads", producing a continuous pattern of embroidery. Each
embroidery head is a sewing machine with multiple needles for different colours, and is
usually capable of producing many special fabric effects including satin-stitch
embroidery, chain-stitch embroidery, sequins, appliqué, cutwork, and other effects.
Embroidering the design:
Finally, the embroidery machine is started and monitored. For commercial machines,
this process is a lot more automated than for the home embroiderer. For most designs,
there is more than one colour, and the potential for additional processing for appliqués,
foam, or other special effects. Since home machines only have one needle, every colour
change requires the user to cut the thread and change the colour manually. In addition,
most designs will have a few or many jumps that need to be cut. Depending on the
quality and size of the design, stitching out a design file can require a few minutes or an
Before computer was affordable, most embroidery was completed by "punching"
designs on paper tape that then ran through a mechanical embroidery machine. One
error could ruin an entire design, forcing the creator to start over. This is how the term
"punching" came to be used in relation to digitizing embroidery designs.
In 1980, Wilcom is thought by many to have introduced the first computer graphics
embroidery design system running on a mini-computer. However, old timers often
debate this. Melco created the first embroidery sample head for use with large Schiffli
looms. This sample head became the first computerized embroidery machine marketed
to home sewers. The sample head was needed to avoid sewing out the sample for the
Schiffli loom and taking up valuable production time. Schiffli looms spanned several
feet across and produced, lace, patches and large embroidery patterns. The economic
conditions of the Reagan Years, coupled with tax incentives of the day for in-home
business, helped propel Melco to the top of the market. At the Show of the America's in
1980 Melco showed the Digitrac. The original digitized design was produced at 6 times
the size it would eventually be sewn out. The Digitrac consisted of a small computer,similar in size to today's Blackberry Devices, mounted on an X and Y axis on a large
white board. It sold for $30,000. The original sample head with one needle sold for
$10,000 with a 1" paper-tape reader, and 2 fonts. The digitizer would mark common
points of the design to create elaborate fill and satin stitch combinations. Melco is the
result of an international distribution network formed by Randal Melton and His
partner Bill Childs. Melco patented the ability to sew circles with a satin stitch, arched
lettering generated from a keyboard. An operator would "digitize" the design into thecomputer using similar techniques to "punching", to create a 1" paper tape, or later to a
floppy disk. This design would then be run on the machine. The machine would stitch
out the digitized design. Wilcom enhanced this technology in 1982 with the
introduction of the first multi-user system that allowed more than one person to be
working on a different part of the embroidery process, streamlining production times.
Brother International got into the embroidery business as a result of being contracted by
several computerized embroidery companies to provide sewing heads. Their sewing
heads were mounted and branded on several different brands of computerized
embroidery machines. Adler was also a common choice. Later Tajima, from Japan,
provided sewing heads that were capable of using multiple threads. Singer failed toremain competitive during this time. Melco was acquired by Saurer in 1989.
Recently Singer was acquired by Affiliates of Kohlberg & Co., L.L.C. ("Kohlberg"), a
leading U.S. private equity firm specializing in middle-market investing, they also
acquired VSM is a leading supplier of high-end consumer sewing machines and
accessories under the Husqvarna Viking and Pfaff brands.
Saurer and Wilcom, Tajima, Brother, began to innovate. The early functionality of thecomputerized commercial systems were adapted and marketed to companies such as
Janome for home use.
As costs have fallen for computers, software, and embroidery machines, computerized
machine embroidery has grown in popularity since the late 1990s. Many machine
manufacturers sell their own lines of embroidery patterns. In addition, many individuals
and independent companies also sell embroidery designs, and there are free designs
Threads, the most important component for this sector, are easily available in the
country. Demand for embroidery thread in the country is growing at a rate of around
seven per cent per annum. And most of the major thread manufacturers are expanding
capacities. Says
Mr. Agarwal, "Threads are easily available in the country, but there is scope for
improvement in quality. We have our own in-house thread manufacturing facility, as
we are probably the largest consumer of thread in the country. This helps us to control
costs. In case of certain requirements, we have to import threads from Thailand, Europe
for better strength, twist, etc."
Realizing the need for quality embroidery yarns, Indian Rayon has ventured into the
manufacturing of viscose embroidery yarns. Consumption of embroidery yarns in the
country stands at around 11,000 tons per annum, of which viscose accounts for a major
share. According to Mr. K D Joshi, vice president, marketing, Indian Rayon, "We have
begun test manufacturing and marketing of this yarn, realizing the demand potential.
Moreover, around 3,500 multi-head computerized embroidery machines are being
installed in Surat, around 1,500 such machines are getting installed in Mumbai, and a
similar number each in Tirupur, Bangalore, Coimbatore, Ludhiana. All these units will
require high quality embroidery yarns. Our yarns offer 850 stitches per minute, as
against other yarns that lend themselves to 650 stitches per minute maximum." Indian
Rayon is now stabilizing the dyeing processes, to fine-tune the quality of the yarn. "We
are improving the colour fastness of the yarns, ensuring azo-free dyeing, etc. We will
be starting commercial production by December this year, or by January next year. Weare aiming at getting 10 per cent of the market share by 2006-07," said Mr. Joshi. While
viscose yarns are the most widely used in embroidery, cotton, polyester and metallic
yarns are also used. However, a large part of the production of these threads takes place
in the unorganized sector; with units have a capacity to manufacture 5 tones to 60
tonnes of embroidery thread per annum. As for the machinery, the industry has to
import embroidery machines from Germany, Japan, Taiwan, and China."
Organization structure is a graphic means or a record depicting vividly the formal
organization structure and shows the formal superior – subordinate relationship. Itshows who supervises and controls whom and how the various units are inter-related.
The Organizational structure of the AMTEK INDUSTRIES is:
rolling of threads in bobbins which are being placed in the embroidery machine and
helping the operator during the framing of fabrics in the machinery.
RAW-MATERIALS USED IN MACHINE PRODUCTION:
The raw material used for the production is
FABRICS
THREADS
METALIC YARN
SEQUIN
STONE
CORDING
PRODUCTION PROCESS:
The PRODUCTION PROCESS of AMTEK INDUSTRIES PVT LTD is follows, they
are as under:
APPROVAL OF DESIGN.
DIVISION OF FABRICS.
SUPPLY OF FABRICS.
INSERTION OF DESIGN.
RUNNING OF DESIGN.
FINNISHING PROCESS.
APPROVAL OF DESIGN:
The production process starts from approval of design by customer. In this stage the
customer who is in need of embroidery works on fabrics he approve the design given
by the company. Approval of design is in the scene selection of particular design from
various designs.
DIVISION OF FABRICS:
Once the customer approve the design of fabrics, the HEAD OF DEPARTMENT makedivision of fabrics as per program, per design and per colour, in the scène how many
The finishing department of AMTEK INDUSTRIES PVT LTD is under the
MR.MUSTAQIM and supervised by two experienced persons MR.NASIR and
MR.KADIR, and MR.SAWOOD is foreman. The finishing department consisting of 48workers under which the works are divided among the skills and experienced, in the
sense 10 workers are engaged in trimming, 2 is for scallop cutting , 8 is for alteration
and so on.
The process of FINISHING is gone under 9 steps .These can explain as under:-
1. TRIMMING STAGE
2. ALTERATION STAGE
3. CHECKING STAGE
4. IRONING STAGE
5. MEASURING & CUTTING STAGE
6. CHECKING & FOLDING STAGE
7. PACKING STAGE
8. PACKAGING STAGE
9. DELIVERY OF GOODS
PROCESS OF FINISHING
After the machine production the product moves through following stages.
The first step involved in finishing process is TRIMMING STAGE . Under this stage
the workers check the embroidery done by machine and cut off the threads which come
out off the design and the sticker is place where the embroidery design is not designedaccurately and it is corrected by making alteration which would be explained in second
stage.
ALTERATION STAGE:
After the trimming process the next step is making ALTERATION where ever
necessary. At these stage workers make alteration using sewing machine in place where
the sticker is being placed by the worker in trimming stage. Hence the alteration work
is done.
CHECKING STAGE:
The checking is the third stage of finishing process. Under this process of finishing the
workers will check the embroidery made by both embroidery machine and sewing
machine and also checks the oil or grease which may misleads during the machine
production. If while checking the oil or grease is found then the product will moves to
the hands of workers who is engaged in removal of dirt by using the thinner oil and
again if any further alteration is needed then again will be done. Hence in these ways
checking is being done.
IRONING STAGE:
After taking the above mentioned steps the product will moves to the IRONING
STAGE. In this stage ironing is being done using machinery.
ATTACHING STONE:
After the completion of ironing the stone is attached to the fabrics as per
customer requirement. This stage is optional, because the attaching stones will
be made only if the customer is in need for particular design.
Place includes company activities that make the product available to target consumers.
The company must identify recruit and link various marketing facilitators to supply its products and services efficiently to the target market. It must understand the various
types of retailers, wholesalers and physical distribution firms and how they make their
decisions.
The selling areas of the AMTEK:-
Since it is Multinational company it export their product to the foreign countries like
KSA (Kingdom Of Saudi-Arabia, Nigeria, Somalia, Jabuti, Sudan, Senegal, Syria; but
in India only in Mumbai).
Marketing Distribution Channel in AMTEK INDUDTRIES PVT LTD:
Distribution is like blood circulating system of human body. Distribution Channel
consists of intermediaries operating in movement of goods from primary products to
the ultimate consumers. These intermediaries are merchant middlemen such as
wholesalers, retailers, sole selling agents who are specialized in one or more marketing
functions of marketing.
AMTEK industry follows the channel of distribution as mentioned below:
Send a second or third letter if first is ineffectual.
Threaten legal action.Effective credit control
Increases sales
Reduces bad debts
Increases profits
Builds customer loyalty
Builds confidence of financial industry
Increase company capitalization
Sources of information on creditworthiness
Business references
Bank references
Credit agencies
Chambers of commerce
Employers
Credit application forms
Duties of the credit department
Legal action
Taking necessary steps to ensure settlement of account
Knowing the credit policy and procedures for credit control
Setting credit limits
Ensuring that statements of account are sent out
Ensuring that thorough checks are carried out on credit customers
Keeping records of all amounts owing
Ensuring that debts are settled promptly
Timely reporting to the upper level of management for better management.
MAINTANANCE OF RECORDS:
The book of account maintained by the AMTEK INDUSTRIES is only few since it is a
large scale concern because the firm has started his operation last 2 years. Mr. Syed
Afan, who looks after the finance department of the firm, However Mr. Arshad Ahmedundertakes the day to day accounts of the firm. The main books of accounts
HR department is an important functional department .It faces the challenges posed by
the ever changing dynamic environment of today. Amtek industries analyses the needfor new/ additional human resources and provides this based on the requirement.
Amtek industries ensure that its personnel are competent having appropriate education,
training, skills and experience to perform their work which effects product quality. The
future of the company hinges on its ability to –
•Select and recruit persons
•Train and upgrade skill sets
•Extract and retain talent
•Robust performance appraisal and reward system
•Evolve performance parameters with respect to key result areas
FUNCTIONS OF HR
Taking care of new recruits and takes necessary actions for their smooth
settle-down in the new environment.
Leave details of all the employees and maintaining the record thereof.
Attending the day – to-day problems of the employees and to take correctiveaction settles the issues.
Maintaining and constantly up dating employee’s personal file by giving
incentive, attendance bonus as per their work.
Activities of HR Department
Recruitment
Selection
Training
Human resource can be regarded as the quantitative and qualitative measurement of
workforce required in the organization. Manpower planning may be expressed as a
process by which the management ensures the right number of people at the right place
at the right time for the right job for which they are suited for the achievement of goals
for the company. Amtek industries believe in the HR needs to understand the
complexities of each unit and should be sensitized to the environment in which it
operates. A single solution that will fit all the units is a sure recipe for failure.
Innovative scheme need to be drawn to compensate and reward the employees. HR
needs to be aware of the external environment and market forces.