BOMBAY RAYON FASHIONS LIMITED.pp ghggtx

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1. BOMBAY RAYON FASHIONS LIMITED

2. REPORT SUBMITTED BY 1. SIDDHI SACHIN BHOIR 2. SALONI VINOD MEHER 3. SNEHAL GANESH TAMORE 4. SHRADDHA NAMDEV KENI 5. DIVYA KESHAV KADU 6. MANALI DINESH DANDEKAR 7. ASMIKA UMESH BHOIR

3. ACKNOWLEDGEMENT We extent our gratitude to H.R . Mr. sanjay chawhan for providing and support during the project . He has been a great help through the making of the project. We thank the BRFL for giving the opportunity to work on such a relevant topic. We also to thank the colledge faculties and H.O.D. Mr. ramteke for their help and others who are indirectly responsible for the completion of this project. Date : Place : Boisar

4. HISTORY OF BRFL 1986 : MR. Janardhan Agrawal established the Bombay rayon group 1190 : Maharashtra gets its first fabric manufacturing facility . 1998 : Bombay rayon group commences export of fabrics . 2005 : Bombay rayon group business is consolidaled into BRFL . 2010 : BRFL established the worlds largest fabric processing capacity of 5 lakh meters day at Tarapur . 2010 : BRFL acquires STI India Ltd, a world class producer of 100% cotton yarn . ABOUT COMPANY DIRECTOR: Prashant Agrawal OFFRESSION PRESIDENT: Sudhir Bhoir BUSINESS PRESIDENT :Sanjay Bihani PLANT HEAD : Manoj Shrivastav TOTAL MANPOWER: 2000+

5. Introduction OF TEXTILE Clothing and textiles reflect the materials and technologies available in different civilization at different time. The variety and distribution of clothing and textiles within a society reveal social customs and culture. Textile is a fabric that is knitted or woven and mode from yarn thus, textile industry is responsible for taking row material and convert it into a finished product . The textile industry in India traditionally , after agriculture is the only industry that has generated huge employed for both skilled and unskilled labour in textiles the textiles industry continued to be second largest employment generating sector in India.

6. SCHEDULE FOR INPLANT TRAINING TRAINING DATES DEPARTMENT RESPONSIBLE 16 / 05 / 19 18 / 05 / 19 Rewinding Mr. Mihir Gandhi 20 / 05 / 19 21 / 05 / 19 Warping Mr. Mihir Gandhi 22 / 05 / 19 23 / 05 / 19 Sizing Mr. Mihir Gandhi 24 / 05 / 19 25 / 05 / 19 PPC Mr. Samir Deshamukh 27 / 05 / 19 28 / 05 / 19 Q.A Mr. Jitendra Shahu 29 / 05 / 19 30 / 05 / 19 Auto Drawing Mr. Ghirish Goyal 31 / 05 / 19 05 / 06 / 19 Loomshed Airjet Mr. Dilip Sakiya 06 / 06 / 19 08 / 06 / 19 Loomshed Toyata Mr. Hitesh 10 / 06 / 19 12 / 06 / 19 Loomshed Rapier Mr. Ramesh Patole 13 / 06 / 19 14 / 06 / 19 Inspection And Dispatch Mr. Vasant Kadam

7. PRODUCTS OF BRFL Viscose Filament Textile Yarn Cotton Filament Polyester Filament Lycra Filament

8. HUMAN RESOURCES We are very proud to be part a group which is closely aligned with I ndian Nationalism and our long history of existence competitive market has taught us few lessions on the art of survival. We are a system and strong process driven organization where TQM as a core philosophy is embedded in our culture which helps us take care of our customer needs through high employee engagement initiatives. Our team comprise of individuals from various disciplines and skill sets aligned with our business plans and requirements. If you want to be motivated team, you can apply online either for current or future opening with us.

9. MANAGEMENT TEAM Prashant Agrawal :- Director Sudhir Bhoir :- Office resident president Sanjay Bihani :- Business President Manoj S hreevasatv :- Plant Head

10. BRFL MARKET EXPORT MARKET DOMESTIC MARKET Bangladesh India UK England US Shrilanka

11. GENERAL PRESENTATION WEAVING What is weaving? Weaving is a method of textile production in which two distinct sets of yarn or threads are interlaced at right angles to form a fabric or cloth . The longitudinal threads are called the warp and the lateral threads are the weft filling.

12. Essential motion of a weaving loom Primary motions of a weaving: In order to interlace warp and weft threads to produce a fabric on any type loom, three operations are necessary: 1 ) Shedding 2 ) Picking or filling or weft insertion 3) Beating up Secondary motions of weaving: 4) warp let- off 5) take-up

13. REWINDING HOD- Mihir Gandhi Supervisor – Sandip Kini Vishal Patil No.of M/C – 11 Name of M/C – Peass Schlafhorsl Winding is one of the most important operation, which in mainly occurred in spinning section. Besides, it’s is also important in fabric manufacturing. In fabric manufacturing, directly winding is not so much important, but rewinding is so important. The creation of large yarn packages that can be easily unwound, is called winding. This makes using the yarn on subsequent machines both easier and more economical.

14. OBJECTIVES OF WINDING : Winding process has some objectives which are given as below: 1. To transfer yarn from spinning bobbin packages to convenient yarn package. 2. To improve the quality of yarn. 3. To get suitable yarn package. 4. To get a quality fabric. 5. To get good warp yarn. 6. To empty the spinner’s bobbin so that it can be used again. 7. To remove dust and clean the yarn. 8. To reduce labor cost. 9. To store the yarn. 10. To improve the efficiency of yarn for next process.

15. REQUIREMENTS OF WINDING Winding process should be accurate for accelerate the next fabric manufacturing process. Winding process should fulfil the following requirements: 1. Winding process should be easy. 2. Characteristics of the yarn should not be changed. 3. Winding faults should be minimize. 4. Yarn package size and shape should be suitable. 5. Winding process should be economical. 6. Yarn package should be economical. 7. Yarn package should be cheap in cost. 8. Avoid excess looseness or tightness. 9. Exact package hardness. 10. In winding, yarn knots should be small in size and amount of knot should be minimum.

16. WARP TOTAL MAN-POWER :- 39 SUPERVISER :- SANDIP KINI , VISHAL PATIL HOD :- MIHIR GANDHI TOTAL M/C :- 11 NAME OF M/C :- PEASS SCHLFHORS-9 SSM :- 2 OFF M/C SPEED :- 600 RPM WEFT SUPERVISER :- RAJENDRA MINAJI , SUNIL PATVARDHAN TOTAL M/C :- 7 (1 OFF ) TOTAL MAN-POWER :- 11 WEFT 15 SURPLUS 4 HELPER 8 – WEFT 43 - TOTAL

17. warping HOD – Mihir Gandhi Supervisor –Raj Prakash Vinay Singh NO.of M/C -12 (2 off) Name of M/C –Karl Mayer Warping is the first step of fabric manufacturing process. After winding, warping is process done for making a weavers beam. Weavers beam is produced from a set of yarns of same yarn count or different. In most of the cases we see that different yarn count is use for making sacking fabrics in jute mills. But most of the fabrics are produced from same yarn count. It is noted that all requirements are depends on the fabric structure. Production of weavers beams depending on the fabric structure. Fabric structure plays an important role in fabric manufacturing process. In textile language; Warping is defined as the parallel winding of yarn from cone or cheese package on to a warp beam. It is needed to confirm that warp beam is make a good warp yarn otherwise weaving performance will be hampered.

18. OBJECTIVE OF WARPING 1. To wound up fixed length of yarn on to a warp beam. 2. To increases the weavability of yarn. 3. To increases the quality of yarn. 4. To make re-useable small package. 5. To increases the production. 6. To make dynamic next process. IMPORTANCE OF WARPING Warping process play an important role in fabric manufacturing followings are the most common importance of warping. 1. Warp beam are constructed by warping. 2. Parallel yarn sheets are constructed by this process. 3. Small package are combined by this process. 4. Long length of the warp yarns is found in this process. Small package re-useable by this process . SECTIONAL WARPING Sectional warping is one of the important process of textile weaving where equal length of yarn is wound first in small sheets or section on a drum. After that is transferred to the beam from the drum in the form of a sheet……there are some major difference between sectional warping and high speed warping.

19. TYPES OF CREEL V- CREEL RECTANGUULAR MAGANIZE TOTAL MAN-POWER :- 90 SUPERVISOR :- RAJ PRAKASH , VINAY SINGH , MAHAVIR SINGH TOTAL M/C :- 12 ( 2 OFF ) MACHINE SPEED :- 450 RPM

20. DIRET WARPING Warping is the process Where ends form a numbers of cons cheeses are collected to form a sheet of yarn comprising of pre-deter mind numbers, length, tension and with which goes to form the weavers beam. Yarn in the sheet will be of some tension, uniform spacing and parallel to each other and will be wound on to a beam called warpers beam. DIRECT WARPING MACHINE SPECIFICATION Machine name : Direct warping machine. Country origin : west point, USA Model no : 701 creel capacity : 434

21. SIZING HOD – Mihir Gandhi Supervisor – Uday Bhan Chirnjiv Borah No. of M/C – 6 (2 off) Name of M/C –Karl Mayer Sizing is the process of applying adhesive coating on the surface of yarn. This process is dome after completing warping process. It is one the most important process to achieve optimum weaving proficiency specially for filament and blended yarn.

22. Following characteristics of yarn have changed 1 increasing yarn elasticity 2 increasing weight of yarn 3 increasing frictional resistance of yarn 4 increasing strength of yarn and 5 increasing smoothness of yarn.

23. OBJECTIVES OF SIZING 1 It is used to remove the projecting fibres from the yarn surface. 2 This process is used to maintain required quality fabric. 3 This process is used to develop the weave ability of warp yarn. 4 It is used to reduce the hairiness of warp yarn. 5 It is used to increase the elasticity of warp yarn. 6 It is used to increase smoothness of warp yarn. PROPERTIES OF SIZED YARN 1 yarn strength: higher, 2 yarn diameter : higher, 3 Smoothness : lower, 4 Hairiness : lower, 5 Absorbency : lower, 6 Frictional resistance : increase 7 Weakness : lower; 8 Flexibility : lower;

24. chemicals SoloACT -SFR (SPECIAL STARCH) INNOTEX MAIZE STARCH-{ SHT}-FNR MAIZE STARCH-{CRS}-JV OVA-T-25 ALTRA STAT VK MULTI WAX SL.PLAST SOFTNER ELVANOL SC-5 FINN FIX ARKOFIL POLYCON UK 40 KING SIZE ARKOFIL (CMS ) TEXO-99 CS-20 AO-60 AEKOFIL CP INNOTEX (CMS ) SUNNY ST-VK SIZE PICK UP TEXTILE AW(FB) PSCICON AW T-17

25. AUTO DRAWING HOD – Girish Shah Supervisor –Ram Pravish Manoj Rao No. of M/C – 4 M/C SPEED – 120 RPM Define : Drawing is also called as drafting. Drawing reduces a soft mass of Fibre to a firm uniform strand of usable size. OBJECTIVES OF DRAWING 1To straighten the crimped culed & hooked fibres. 2 To make the fibre parallel to their neighbors . 3 To improve uniformity of fibres drafting and doublings. 4 To reduced weight per length unit of sliver . 5 To remove dust from slivers. 6 To blend raw material of same hank perfectly.

26. PRODUCTION PLANNING AND CONTROL (PPC) Important role in apparel export PPC is one of the most important departments in the apparel industry. It place an business. It helps to build up strong relationship with the other departments to obtain maximum output from the export order. 1) Order receive = finished fabric 2 ) Calculation = grey- Warping- 3) Grey yarn requirement = dyed yarn requirement. 4) Planning Delivery time Loom plan 1) production 2) machine type :- a ) dobby b ) Cam FORMULAS 1) Warp Qty in kgs = epi*reed space/ 1693* wp . count * order Qty. (warping) 2) Weft Qty in kgs = ppi * reed space / 1693*weft count* order Qty. (grey qty.)

27. LOOMSHED AIRJETLOOM HOD – Dilip Sakiya No. of M/C -304 Name of M/C – Picanol (Air jet ) M/C Speed – 1000 RPM Air jet loom is a shuttleless loom that is used a jet of air to propel the weft yarn through the warp shed. It is one of two types of fluid jet looms, the other being a water jet loom, which was develop previously. Fluid jet looms can operate at a faster speed than predecessor looms such as rapier loom, but they are not as common. The machinery used in airjet consist of a main nozzle, auxiliary nozzle or realy nozzels and a profile reed .

28. RAPIER LOOM HOD – Ramesh Patole No. of M/C – 88 Name of M/C – Picanol (Rapier) M/C Speed – 500 RPM A rapier loom is a shuttle less weaving loom in which the filling yarn is carried to the shed of warp yarns to the other side of the loom by finger like carries called rapiers. A stationery package of yarn is used to supply the weft yarn in the rapier machine. One end of a rapier a rod or steel tape, carries the weft yarn. The other end of the rapier is connected to the control system. The rapier moves across the width of the fabric carrying the weft yarn across through the shed to the opposite side. The rapier is then retracted, leaving the new pick in place.

29. INSPECTION AND DISPATCH HOD – Vasant Kadam Fabric inspection is an important aspect followed prior to garment manufacturing to avoid rejects due to fabric quality and faced with an unexpected loss in manufacturing. Fabric inspection is the done for fault/defect rate, fabric construction, fabric weight ,shrinkage, end to end or edge to edge shading, colour, hand feel, length/width, print defect and appearance. Various types of faults found in woven fabric – • Bad selvedge • Broken ends or warp • Broken pics or weft • Loose warp • Loose weft or snarl • Double end • Tight end • Float of warp 4 point system in fabric inspection- Defects Classification: The 4 point system assigns 1,2,3 and 4 penalty points according to the size, quality and significance of the defect. Whenever errors are recognized during fabric inspection under 4 point system and defect must be assigned a number of points depending on the severity or length.

30. GREY INSPECTION In grey inspection where the inspect the fabric fault. The grey fabric come from the party or own production department. The machine name :- textile enterprice . It is made in india The speed of the machine :-upon the quality of fabric. like 10 mtr to 15 mtr in 1 min. Process :- unless. And until specified 4 point inspection system shall be followed. During inspection parameters like quality verification, width, type, selvedge type and it quality EPI, PPI, harriness intencity etc. Shall be checked addition to defect. Selvedge in case prove quality shall be checked. An approved against standard and approve fabric swatch. Fabric inspection shall be carried out at the speed of 15 mtr to 20 mtr per min

31. The Faults are such as following Yarn slub . Lfole knot.l Broken end Short pick. Starting mark. Thick place. Double pick. Miss end (warp checked pick) Loose pick (weft checked pick)

32. Thank YOU !