CHAPTER I

INTRODUCTION

1
 INTRODUCTION

TEXTILE INDUSTRY IN INDIA

Production involves the step by step conversion of one form of material into another
through mechanical or chemical processing to create or enhance the utility of the products or
service output. It is the process of transforming the resources into goods or service that
people need or want. Production is a series of process dealing with concept and mental and
physical skill craftsman and consists of changing the shape, size and properties of material
and ultimately converting them into more useful articles. Production management tells how
to manage human efforts in a productive environment.

The production may be defined as "an organized activity of transforming the raw-
materials into finished goods". India has abundant availability of a wide variety of crops,
fruits, vegetables, spices, flowers, livestock and seafood. Diverse climatic conditions and a
long coast-line have contributed to India's position as a leading garment producer.The
'Textile industry in India's traditionally, after agriculture, is the only industry that has
generated huge employment for both skilled and unskilled labour in textiles.

The textile industry continues to be the second largest employment generating

sector in India. It offers direct employment to over 35 million in the country. The share of
textiles in total exports was 11.04% during July 2010, as per the 'Ministry of Textiles'. During
2010 - 2012, Indian textile industry was pegged at US $55 billion, 64% of which services
domestic demand.

2
 HISTORY

The archaeological surveys and studies have found that the people of Harappan
Civilization knew weaving and spinning of cotton for thousands of years ago. Reference to
weaving and spinning materials is found in the Vedic Literature also.

Since ancient times Indian Textile Industry has been well known for her textile goods.
During the colonial regime the traditional textile industry of India was virtually decayed.
However in the early nineteenth century the modern textile industry took birth in India, when
the first textile mill was established at Fort Gloster near Calcutta in 1818. Indian Textile
Industry is one of the India's oldest industries and has a formidable presence in the national
economy as it contributes to about 14% of manufacturing value-addition, accounts of about
one-third of our gross export earnings and provides gainful employment to millions of
people.

Indian Textile Industry has earned a unique place in our country. It is among one of the
industries which were earliest to come into existence. It accounted for 14% of the total
industrial production, contributes to nearly 30% of the total exports and is the second largest
employment generator after agriculture. This industry provides one of the most basic needs of
people and holds importance, maintaining sustained growth for improving quality of life. It
has an image of self-reliant industry, from the production of raw-materials to the delivery of
finished goods, with substantial value-addition at each stage of processing which forms a
major contribution to the country's economy. Thus, without any doubt it is clear that our
textile industry is a leading one among all others in the world itself.

3
 INDIAN TEXTILE INDUSTRY

Cotton Textile Man Made Silk Woollen Jute

Organized sector Decentralized sector

Cotton Mills [Private Public &

Co-operative

Hanldoom [Cloth] Powerloom

[Cloth]

Cotton Textile Cotton Textile

(Fig 1.1)

PRODUCTION
India is the second largest product of fiber in the world and the major fiber produced is
cotton. Other fibers produced in India include silk, jute, wool, and manmade fibers. 60% of
the Indian textiles industry is cotton based.

4
The strong domestic demand and the revival of the Economic markets by 2009 has led to
huge growth of the Indian textile industry. In December 2012, the domestic cotton price was
up by 50% as compare to the December 2010 prices. In the causes behind high cotton price
are due to the floods in China and Pakistan. India projected a high production of textile [325
lakhs sales for 2010-12]. There has been increase in India’s share of global textile trading to
7% in 5 years. The rising prices are the major concern of the domestic producers of the
country.

 Man-made fibers: These includes manufacturing of clothes using fiber of filament

synthetic Yarns. It is produced in the large power loom factories. They account for the
largest sector of the textile production in India. This sector has a share of 62% of the
India's total production and provides employment to about 4.8 million people.

 The Cotton Sector: It is the second most developed sector in the Indian textile industries.
It provides employment to huge amount of people but it's production and employment is
seasonal depending upon the seasonal nature of production.

 The Handloom Sector: It is well developed and is mainly dependent on the SHGs for their
funds. Its market shares is 30% of the total cloth produced in India.

 The Woolen Sector: India is the seventh largest wool in the world. India also produces
1.8% of the world's total wool.

 The Jute Sector: The jute or golden fiber in India is mainly produced in the Eastern states
of India like Assam and West Bengal. India is the third largest producer of jute in the
world.

 The Sericulture and the Silk Sector: India is the second largest producer of silk in the
world. India produces 18% of the total silk. Mulberry, Eri, Tasar and Muga are the main
types of silk produced in the country. It is a labour intensive sector..

OBJECTIVES OF THE STUDY

5
PRIMARY OBJECTIVE

 To analyze and interpret the performance and efficiency of the production department of
the organization.

SECONDARY OBJECTIVE

 To identify production strength and weakness of the firm.

 To understand about the historical performance of the society.

 To determine the production status of the society.

 To understand the working method of the firm.

 To analyze and evaluate the firm's labourer's performance.

 To evaluate the expectations of the labourer’s of the firm.

SCOPE OF THE STUDY

This study is conducted to know about the working method, production efficiency and
performance of the company. A better management is the asset of the company. It helps to
have a clear understanding among the labourers’. Financial status of the firm has to be
analyzed and interpreted for the better performance. Production analysis will help to know
the strength and weakness of the firm. Quality control is another important area to be strictly
monitored. Proper training has to be imparted to the labourers from time to time. This will
help to reduce the loss due to mismanagement.

This study is conducted to analyze the production efficiency and performance of the firm.
It have mainly 5 production units such as dyeing unit, winding unit, weaving unit and cutting
and sewing unit etc. It studies about the manufacturing process, raw-materials used etc. Data
were obtained from the placement training inside the company.

Various production units are visited for analysis. All the data collected are from the
year of 2011-14 and they are analyzed and evaluated in this project work and it also provides
suitable suggestions and conclusion based on finding.

PROBLEMS FACED BY THE COMPANY

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 Well organized competitors.

 Increase in the price of raw-materials.

 Non availability of the raw-materials.

 Insufficient waste management facilities.

 Lack of energetic and educated young workers.

 Inability to capture the market demand due to lack of advertisement facility

LIMITATIONS OF THE STUDY

❖ The analysis is based on the industrial visit conducted in the company and the accuracy of
the report on the basis of my observations and understanding.

❖ In a given short time it is difficult to cover all the areas and aspects of the firm.

❖ All the statistical tools have its own limitations. So the same is assumed to be in the
limitations of the study.

❖ Production performance analysis is based on my visit in the company and the result is
based on my understanding and knowledge and also through the information received
from the staff.

❖ The conclusion and inferences are drawn only on the basis of interview and it may be
biased.

The limitations of all the tools of analysis adapted will be applicable here also.

METHODOLOGY

The study is partly descriptive and partly analytical. Marketing research is as possible
yielding maximum information with minimum expenditure. The study is primarily based on
my observation done under the placement training conducted in this company. Besides, the
information was gathered through discussion with the officers of the firm. Further, personal
interview was done with the various personnel working in the firm.

SOURCE OF DATA

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 Both primary and secondary sources of datas are used in this work.

■ PRIMARY DATA

Primary data required for the study are collected from the following ways:

 Daily visit to the factory.

 Direct interview with various departmental heads.

 Informal interview with the workers.

■ SECONDARY DATA

Secondary data required are collected from the following ways:

 Journals and day books of the company.

 Other official records of the company.

DURATION OF THE STUDY

This project was done by me for a period of 21 days starts from 10/12/2015 to
31/12/2015.

8
 CHAPTER-II

INDUTRAIL PROFILE

 HANDLOOM EXPORT DEVELOPMENT SCHEME

 HANDLOOM INDUSTRY IN KERALA-AND ANALYSIS

 HANDLOOM INDUSTRY IN KANNUR

INDUSTRY PROFILE

India has abundant availability of a wide range of crops, fruits, vegetables, spices,
pulses, flowers, livestock and sea-food. Diverse climatic conditions and long coast line have
contributed to India's position as a leading garment producer.

The Indian Textile Industry occupies a vital place in the Indian economy and
contributes substantially to its exports earnings. Textiles exports represent nearly 30% of the
country's total exports. It has a high weight age of over 20% in the national production. It
provides direct employment to over 15 million persons in the mill, power-loom and hand-

9
loom sectors. India is the world's second largest producer of textiles after China. It is the
world's third largest producer of cotton- after China and the USA- and the second largest
cotton consumer after China. The textile industry in India is one of the oldest manufacturing
sectors in the country and is currently it's largest.

The textile industry occupies an important place in the Economy of the country
because of its contribution to the industrial output, employment generation and foreign
exchange earnings. The textile industry encompasses a range of industrial units which use a
wide variety of natural and synthetic fibers to produce fabrics. The textile industry can be
broadly classified into two categories, the organized and unorganized mill sectors.
Considering the significance and contribution of textile sector in national economy, initiative
and efforts are being to take urgent and adequate steps to attract investment and encourage
wide spread development and growth in this sector.

The handloom industry was established about 2000 years ago and was brought to
England by the Romans. The process was consisted of interlacing one set of threads of yarn
(Warp) with another (Weft). The warp threads are stretched lengthwise in the weaving loom.
The weft, the cross threads, are woven in the warp to make the cloth.

Wearing remained unchanged for hundreds of years until John Kay devised the
flying shuttle which enabled a wears to knock the shuttle across the loom and back again
using one hand only. The speed of wearing was doubled and a single weaves could makes
cloth of any width, where as previously two men sat together at a loom to make broad cloth.
By 1800 it was estimated that there were 250000 handlooms in Britain.

Kerala the greenish land lies between the Western Ghats and Arabian Sea, about
15000 square miles with varying scenic beauty. Kerala is known as epitome of India.
Historically Kerala has long been a land of racial mixture and co-existence.

10
 Tolerance and cosmopolitan are the characteristics of a "Keralite". This may be
attributed to the religious and trade contract, which exited for centuries with outside India.
Handicraft handloom wearing irony works, wearing of coir one well known heritage of
Kerala. Kerala handloom industry carries a vital role in state's economy as well in the field of
the employment.

A very large number of loom are located in rural areas. The rhythm of handloom can
be heard in almost every village in Kerala. There are men and women weaves for whom
weaving is way of life. In early days majority of handloom weavers flowed the hereditary
line. The main communities engaged in weaving are 'Saliyas and Devangas'.

With available information it is clear that the 'Salivas and Devangas' are migrated from
the nearby princely states. Earlier they were producing cloth for their own consumption and
for the need of their village. Increase in production and transport facilities removes the
hindrance of time and exchange of commodities. The skill of weaving was passed from
parents to their children.

During 15-th century, British, French, Portugal use people in Kerala. The thing like
spices, ivory, and beauty of handloom fabrics attracted them. They began to purchase large
quantities and exported to their countries.

After British captured India, they look up and nourished handloom industries for the
purposes. At the end of 18-th century the monopoly came to an end. Since the 19-th century
with the advent of industrial revolution, the English people gave up all.

They start mechanical production in their land. During the period of foreigners the
weavers of Kerala learned all the techniques and they paralleled the way for the production of
furnishing fabrics according to the new style of demand.

During the dawn of 20-th century, Sree Narayana movement influenced Kerala
society by and large prompting the caste based culture to change towards Secular and Modern
Industrious Culture. So many people from traditional Thiyya, Ezhava community had take up
their employment in handloom industry.

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 The women all over the India for their fineness of count and natural colour texture and
gold borders praise the 'Kerala Kasavu Sarees'. Kerala is also known for its cotton handloom
trope popularly known as 'Kara' cloth this has entered in the foreign market and occupied a
proud place in the garment industry.

The secret of Structure and fabrics from Malabar is the excellent structure and texture
of the cloth, unique color combination, wide width (98'-120') and craftsmanship. When we
look back to the history of Kerala, it can be seen that, in 1498 Vascoda Gama. the Portuguese
navigator visited Calicut in Malabar. So it is well known that 15-th century handloom cloths
of excellent qualities were exported to Asian and European countries.

Balaramapuram, in Trivandrum district is the most historically place for handloom

fabrics. The weavers belongs to Saliyas were migrated from Nagar Coil and Thirunelvedi in
Tamil Nadu during the time of Balarama Varma before 250 years.

Hence, they produced super fine 'Mundu and Neriyathu' for the need of royal families.
Still they exist and carry the important part of the total production.

Before 100 years the Jeri from Surat takes to Balaramapuram and 'Kasavu sarees'
production was started. Chendamanalam in Eranakulam district is an important handloom
center in Kerala. Here, they have been producing the 'double mundu and neriyath'. The
distinction of these fabrics is in its structure in the plain structure, they have producing
special effects in weft direction.

Koothmpalam in Thrissur district is also well known for handloom fabrics. Here,
'Devangas' immigrated from Karnataka are engaged in wearing. The 'Kasavu sarees', which
are been produced here, is mostly with half fine 'Jeri'. The middle class people like to
purchase this sarees because of its cheapness. The price of a saree can be reduced from 5000-
1000 by using half fine 'Jeri' instead of pure 'Jeri'.

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 HANDLOOM EXPORT DEVELOPMENT SCHEME

The importance of handloom sector in the National Economy cannot be over

emphasized. On account of having the advantages of flexibility of small scale production,
uniqueness in innovation and adaptability, the handloom sector can contribute towards export
earnings in a big way. Export of handloom therefore been identified as a 'Thrust area' for the
overall development of the sector. The government has been exploring the possibility of
making optimal use of the resources to enhance production capabilities of exportable
products.

In order to provide substantial imputes to export of fabrics, made-ups and other

handloom items from the country, a scheme for the development of exportable products and
their marketing was introduced during 1996-97. Under the scheme assistance is available for
developing exportable products, building up production capacity for export and there after
marketing it.

National and State level Handloom Co-operations, Co-operative Societies and Handloom Co-
operative Societies affiliated to/ registered and sponsored by Councils/ Corporations.
Handloom Export Promotion Council (HEPC), Association of Corporations and Apex
Societies of Handloom (ACASH), Handicrafts and Handloom Export Co-operation (HHEC).
Indian Silk Export Promotion Council (ISEPC). National Handloom Development Co-
operation (NHDC) etc are eligible for assistance under this scheme. Private handloom
exporters can also be assisted through HEPC.

HANDLOOM INDUSTRY IN KERALA- AN ANALYSIS

Kerala has 14 districts from Trivandrum to Kasargod. The handloom industry is

spread all over the state. But the handloom industry is concentrated in certain places. The
southern Kerala is famous for its superfine products like 'sarees, dhothis, set-mundu' etc. The
middle Kerala also engaged with such products. But while going to the northern side called

13
Malabar, the main products changed to coarser varieties like furnishing item, spreads,
lungies, towels etc. The main common production in Kerala is 'thorthu' and Tungies'. Almost
5 lakhs families are depending upon handloom industry.

District wise analysis of handloom industries is given below;

TRIVANDRUM

The capital city has its own historical importance. There are 349 societies and
44700 weavers working with their looms. The products of this district are fine cotton textures
and durries with special design. Balaramapuram is very famous its fine grey saris with
'Kasavu' (Jeri). The other products are 'set- mundu, thorthu, melmundu' etc. The handloom
products are also concentrated in Parassala. Kalathur and Cherayankeezhu etc./

KOLLAM
This district had a few handloom production places. Here, almost 80 Cooperative
Societies with 10271 registered weavers exist. The main products of the district are lungies,
furnishing item. 'Earezhu Thorthu', Sarees, Dhothies etc. Karunagapally, Chattanur and
Kollam are the main places related to handloom in this district. The products are mainly
manufactured for domestic markets.

PATHANAMTHITTA;

There are 7 co-operative societies and 165 registered weavers with looms in this district.
The main products are'lungies and dhothies'.

ALAPPUZHA

Alappuzha is famous for its coir products. Coir weaving is also done with the hands,
But, it is considered as another wing. The main products in this centers are dhothies, sarees,
lungies etc. There are 25 co-operative societies with looms and 2309 weavers in this district.

IDUKKI;

In this district there are 11 societies and 414 with their looms. The main products are
sarees. lungies etc.

KOTTAYAM;

In this district the main products are panimund and lungies, bed sheet sarees etc. There
are 16 co-operative societies with 1853 weavers.

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 ERANAKULAM;

Chennamagalam sarees are famous in Kerala. This fine grey sarees are the of this
district. The products manufactured here are superfine double dhothies, synthetic and silk
sarees... There are 30 societies and 8494 with their looms in this district.

THRISSUR;

The cultural capital of Kerala has an important role in the tradition of Kerala. Here a
traditional variety named 'Koothampally saree's is producing. Koothampally is a place
situated in Thrissur. The other products are set-mundu, woman with half fine jary, dhothies,
lungies etc. There are 30 societies and 6055 weavers.

PALAKKAD;

In this district handloom weaving is very popular in Chettur, Pundungaram,

Kollengode, Peruvemba, Karimpuzha etc. The main products are sarees, dhothies, lungies
etc. Silk saree production also started recently. There are 45 societies and 11236 weavers.

MALAPPURAM;

A number of Muslim weavers are here in this district. Tirur, Tanoor are the main places.
Furnishing items and sarees are main products. There are 13 societies and 2774 weavers.

KOZHIKODE;

The famous "Malabar Looms" came from this place. The "Calico cloth' was also
introduced from this district. The other main products are furnishing products, jacquard bed
sheets, table mats etc. The products are mainly coming from "Malabar Loom'. The products
of Kozhikode have an excellent value in domestic as well as foreign market. Kozhikode,
Quilandi, Vatakara are the main places.

WAYANNAD;
There are only 4 societies in this district and 136 weavers. Much importance is not
given to handloom sectors in this high range district
KANNUR;
Kannur is called as the 'Manchester of Kerala'. The weavers are working mainly in
industrial societies for export of handloom products mainly depends up-on products from
Kannur. The main products are shirtings, jacquard items, furnishing items, crepe, sateen

15
sheets etc. for foreign markets and lungies, earezhu thorthu etc. for domestic markets. There
are 73 societies and 13667 weavers. The main centers are Kannur, Azhikode. Kanhirode,
Panoor, Kuthuparamba, Kalliasseri etc.
KASARGOD;
It is the north most district in Kerala. Here sarees are produced mainly in Kasargod,
Manjeswaram etc. There are 11 societies and 3401 weavers. 'Kasargod sarees' are very
famous in Kerala. Now a days there is very good demand for the silk sarees women with
different colors and ornaments.

HANDLOOM INDUSTRY IN KANNUR

Kannur is known as city of "looms and lores". Kannur was recognized by the Central
Government as the 'Town of Expert Excellence'. Kannur handloom is celebrating 50 years of
handloom export. The traditional handloom industry in Kannur is 400 years old, the
craftsmanship of weavers here has acquired fame with the launching of export of handloom
products.

According to KHEO office bearers, 'Fifty glorious years of handloom exports

have been made possible by the understanding approach of exporters and weavers of
Kannur'.

'The town of Export Excellence' status is one of the main demand of the handloom
exporters here. They say that the town rightly deserves this recognition because exports from
here account for 12% of total handloom exports in the country.

About 15 handloom exporters in Kannur together clock Rs.300 crores turn over.
European and United States firms are increasingly seeking furnishing, tapestries and made-
ups from Kannur handloom. Provided the weave is good. Weavers in Kannur are taking the
tough climb up the quality-skill curve, not on the glitter of Kerala saree, but through its fine
woven furnishing suppliers for export.

16
 CHAPTER-III

COMPANY PROFILE

 LOCATION OF KWCS

 FACILITIES AVAILABLE

 VISION OF KWCS

 OBJECTIVES OF KWCS

 ACHIVEMENTS OF THE SOCIETY

 PRODUCT PROFILE

 PLACE PFORLE

 AUTHORITY AND RESPONSIBILITY

17
 COMPANY PROFILE

The KANHIRODE WEAVERS' CO-OPERATIVE P&S SOCIETY is one of the main

handloom manufacturing unit in Kerala. This society is registered as a co-operative society
under the act of VI of the 1932(Madras) on 16/9/1952 and started its function on
05/10/1952. At that time it's paid-up share capital was only 10,130 rupees. It is also known
as "weaveco".

The main object of the society is to provide regular employment to poor workers at a
reasonable wages and thereby improving the standard of living and economic conditions of
the weavers.

In the initial period, the company as only 200 members and they produced "Thorth" and
"Pudava". They sold these products in their locality by the weavers. Later bullock cart have
used to carry these goods.

The society is engaged in manufacturing various kinds of cotton fabrics which is

suitable for export-market as well as local-market. The 1964-65's was the period, which gave
the society a hope to shine in the textile world and they started to produce shirting, lower
count lungies which were sold different parts of the country through agents.

During 1973-74, the society started to produce crepe fabrics which attached orders of
merchant exporters. Then again started production of furnishing fabrics suitable for export
market and the products to merchant exporters.

The KANHIRODE WEAVERS CO-OPERATIVE P. & S. SOCIETY is an ISO

9001-2000 certified company. It is the first ISO certified handloom co-operative society in
the state. The society has very good market for its products.

18
 The society's address shall be Kanhirode village, Kanhirode post taluk of
Taliparamba. in the Kannur district. Its operation shall be. confided to Kanhirode
and Kuttiattoor amsam in Thalipramba taluk, Munderi and Anjarakandy amsams in Kannur
and Koodali in Telichery taluk.

The company having workforce of 500 workers and 300 working looms with various
width capacity from 48-90 inches. It includes 5 looms for silk. They are also having 30
stitching machines and 2 dehumidification room to keep the geniuses of fabrics.

The company mainly producing different items like lungies, shirting, satens and
printed bed-sheets, bed-spread, dhothies, towels, thorth... For local market furnishing fabrics,
jacquard items, shirting, crepe, bed-sheet, table-cover, napkins, cushion covers etc for export
market. The earn 75% of profit from international markets they produced goods on the basis
for customer requirement.

For the diversification of product the company had established a silk weaving centre
and a jute development centre, quality dying unit etc. The society had availed financial
assistance from central and state government for the following purpose:

 Working capital for handloom development centre.

 Silk weaving unit.

 Quality draining unit.

 Project packaging scheme.

 Jute development centre.

The important requirements for any business activities are land, labor, capital and
organization. This company has permanent building and adequate workforce, storage places
and other working environment requirements as per the Factor. The company also has
adequate equipments for manufacturing as well as other documentation requirements like
computer and other accessories. All these facilities are very helpful in the success of this
society.

19
 The society has a better working condition. The workers enjoy the best working
atmosphere. Like space, machinery, wages etc. fabrics and made-ups manufacturing is not
hazardous to the personnel involved in it. However the company strictly supported to all
mandatory requirements of safety like fire extinguishers, first-aid facilities.

LOCATION OF KANHIRODE WEAVERS' Co - operative P. & S. SOCIETY

Ltd (KWCS)

Kannur "city of looms and lore's" lies in the northern part of Kerala. The KWCS is
located at Kudukimotta. This place is 15 km away from Kannur and it is near to Mattannur.

VARIOUS FACILITIES AVAILABLE IN THE KWCS

1. Cabinet dyeing machine with capacity of 250 kg.

2. Dyeing chamber with capacity of 500 kg.

3. 300 working loom with up-to 90 inches.

4. 10 numbers silk weaving loom width up-to 90 inches.

5. De-humidification rooms for moisture control of fabrics.

6. In-house stitching unit with 30 numbers Juki machines.

VISION OF KWCS

A complete range of hand loom fabrics inheriting age-old tradition of classic warp
well combinations importing modern chrematistics of convenience without compromising on
the core value of quality.

The fabric range has been created through adequate research and expertise that it will enable
Indian Textiles to acquire a competitive edge in global market.

OBJECTIVES OF THE SOCIETY

20
 The primary objective of the handloom industry and the economic area for the purpose of
attaining this of the society is the improvement of conditions of the weavers residing in the object it
shall be competent.

 To raise the money required for the society from the weavers and other by issue of share and by
borrowing by way of deposit.

 To purchase appliances as maybe required for the industry and retail the same either for cash or
for credit to the weavers.

 To purchase and hold in common or lot on improved appliance connected with the society.

 To purchase yarn and other raw materials and advance the same to weaver member who shall
convert them into finished goods and deliver them to the society.

 To pay wages for such conversion and arrange for marketing of the finished goods to the best
advantages of the society.

 To act as the agent for the joint purchase of the domestic and other requirements of its members
and for the sales of their finished products.

 To buy or acquire power looms and accessories and hold them in common or sell them to
members on ready cash or loan for the introduction of the power loom in the handloom sector and
thereby develop the economic conditions of members. /

 To directly exports the products for the execution of the bulk export orders in time. The society
may arrange production from other weaver's co-operative societies or produce, with the
permission of register in order to execute the orders in time.

ACHIEVEMENTS OF THE SOCIETY (AWARDS)

■ The first ISO-9001:2001 certified primary handloom co-operative society in Kerala.

■ The contribution of the society in the field of craftsmanship awarded 'Gold Medal' for
the best performance by Govt, of India. Ministry of textiles during 1993-94.

■ The Govt, of India had selected this society for participation in International Trade
Fair at Frankfurt, Germany during 1995-2004.

■ Sahakarana Mahathwapoorna Award 2006.

PRODUCT PROFILE

21
 Products is the most important and first element of marketing mix. It is very useful to
satisfy the objectives of marketing namely 'profit maximization through consumer's
satisfaction'. If there is no product, there is no producer, no pricing, no distribution or
promotion. The product is the media through which the marketer reaches the consumer.

The KWCS is engaged with manufacturing of handloom fibers and made-ups in

cotton as well as silk. At the initial stages, the society was concentrating only in the local
market and then they started exporting but. now they are again concentrating on local market
only. Manufactured goods are standardized and graded in the process of production itself.

Standardization refers to the establishment of certain standards for the commodity on

the basis of its physical properties or quality. Standardized and graded goods facilitate selling
by description and sample.

The KWCS produced different type of hand loom product for local market and inter-national
market. They are as follows:

FOR LOCAL MARKET:

• LUNGIES

• SHIRTING

• SATIN & PRINTED BEDSHEET

• DHOTHIES

• TOWELS

• THORTH

• SAREE

FOR INTER-NATIONAL MARKET

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  FURNISHING FABRICS

• JACQUARD ITEMS

• SHIRTING

• CREPE

• APROM

• BEDSHEET

• TABLE CLOTH

• CUSHION COVERS

• CURTAINS

• SOFA CAUSES

• SOFA COVERS

• FLOOR MATES

• BOLSTER

• TERRY TOWELS

PLACE PROFILE
Distribution mix or place mix stands for the matching arrangements for the smooth
flow of goods from the producer to the consumer. It is concerned with creation of place, time
and possession utilities. It is the delivery of right products, at right time and at right place.

It includes transportation, warehousing, channels of distribution etc...

TRANSPORTATION:

Production and consumption is linked through transportation. Transportation aids in

selling function by creating place utility of goods. Selection is to be made of the most
efficient, economical rapid and dependable mode of transport for the firm's products, taking
into account railways, roadways, waterways or airways.

23
 The society mainly uses roadways to carry raw materials to the
production center. The make use of depending upon the market they are intended to. In the
case of domestic market, the products are taken to the distributors in a motor truck. The
society has owned a truck for the transportation of the product.

WAREHOUSING:

The place where the goods are stored is known as a warehouse. It creates time utility,
warehouse in a common parlance means a go-down, warehouses embraces storage and help
other marketing functions.

The society has its own place for distribution of products that creates time utility by
adjusting supply and demand, preserving or conditioning the product and obtaining more
favorable demand. The warehouse of the society is at the company itself, (attached to the
weaving mill at Kanhirode).

The yarn bales received are stored off the floor count wise. The dyes and chemicals are
stored in a separate room to avoid exposure to air and probable deterioration. The trims and
accessories are stored in bins or racks. Materials are issued from stores on 'first in first out
(FIFO)' basis.

CHANNELS OF DISTRIBUTION:

It means the ways through which products are made available to the consumers. It
includes a set of marketing intermediaries. It is concerned with creation of possession utility.
The channels of distribution is related with the determination of the number of middle men to
be used, the number of distributors and dealers to be employed on one hand and creation of
franchises agreement, stipulating the obligation of manufacturers and the intermediates and
the legal implications involves in their relationship on the other hand.

24
 In the case of domestic market, the society adopts zero level channel of distribution i.e.;
direct selling. The society sells their products through outlet of their own at Kannur and many
other places.

ZERO LEVEL CHANNELS

KWCS CONSUMERS

(Fig 3.1)

In the case of foreign market, the society adopts two level channel of distribution, that is,
there are two intermediaries, they are merchant exporters and dealers. The society offers 5%
to 30% commission to merchant exporters.

KWCS

MERCHANT EXPORTERS

DEALERS

CONSUMERS

FIG 3.2

Merchant exporters are middlemen between the party and the society. They collect orders
from the parties and the society receives orders from them. According to these orders
products are produced by the society.

25
AUTHORITY AND RESPONSIBILITY

PRESIDENT:

He is responsible to:

 To take policy divisions of the company.

 To make investment division, long term financial

commitments and diversification plan of the company in consultation with the

BOD.

CHIEF EXECUTIVE/SECRETARY:

He is responsible to:

• Define and document the company's quality policy and objectives.

• Provide adequate resources for implementing QM.

• Discharge the duties of purchase manager.

• Over all operation of the company.

• Allocation of various resources to the different departments.

• Assessing the training needs of the HODs and imitates training programs.

• New customer development.

• Attend the fair develop new markets and new customers.

• Produce orders for the company.

• Handling customers compliant.

• Define company long term business plans.

26
 3. Management Representatives:

He is responsible to:

• Establish, implement, maintain and monitor quality system.

• Control the distribution of QM, SOP, WI and TAD.

• Plan and arrange internal quality audit.

• Co-ordinate the activities concerned with the external agencies.

• Responsible to reporting to the top management on the performance quality

management.

4. Manager- Raw-Material
Purchase:

He is responsible to:

• Establish and document specification for raw materials and accessories.

• Assess the availability of raw material and accessories as per the

requirements.

• Purchase the raw material through purchase order.

• Development the new raw material suppliers.

• Act as factory manager.

• Maintain inspection status of raw materials and accessories in the store.

• Production planning and control activities

• Responsibilities for issue of materials, stock updating and material

reconciliation.

5. Weaving Master:

He is responsible to:

• Plan and execute the production activities at the weaving & production units.

• Allocation of work to various workmen.

27
 • Ensure the product characteristics during production.

• Assess the training needs of the work force of the weaving dept.

• Initiate the corrective action in the dyeing and weaving dept.

• Preserve the approved samples /customer samples with proper identification.

• Act as the custodian.

• Maintains of weaving machine.

6. Quality Assurance Supervisor (QAS):

He is responsible to:

 Ensure inspection of yarn, dyes and chemicals accessories, fabrics and made ups, and
garments at all stages.
 Maintain inspection of raw materials in process and finished goods.
 Arrange proper handling, storage and presentation of raw materials and accessories.
Prepare suppliers evaluation record.

7. Production Manager:

He is responsible to:

 Develop new samples as per the requirements communicated by CE.

 Develop new designs from the existing samples.

 Prepare costing details of samples.

 Ensure the all required accessories are available

 in the unit before made ups the production

 started.

 Initiate the corrective action and preventive action as necessary.

 Help the CE in matter of marketing activities.

 Responsible for verification of yarn, dyes and chemicals.

28
8. Dyeing Master:

He is responsible to:

 Production planning and control in the dyeing department.

 Maintenance of the dyeing machines.

 Prepare the recipe as per the shades required.

 Maintain the master shade card,

 Approved dyed yarn before issued to further processing.

 Safe keeping of dyes and chemicals in procurements

9. Manager Export and Administration

He is responsible to:

• Handle all export/import and banking formalities.

• Liaise with cleaning agents regarding the shipments of merchandise.

• Communicate with customers.

• General administration of the company.

• Carry out stock verification activities.

10. Business Manager:

He is responsible to:

• Assist the secretary to produce orders.

• Assist the secretary to co-ordinate with business houses and buying agents.

• Assist the secretary to handle customers' complaints.

DETAILS OF THE SOCIETY (KWCS)

Name of the society The Kanhirode Weaver's Co-operative P & S Society

Trade Name WEAVECO

29
Date of registration 6/09/1952
Address P.O Kanhirode, Koodali (via), Kannur (dst),
Kerala- 670592
91 -0497-2857259:91 -0497-2857865
Tele Fax 91-0497-2858546
weavecoop@bsnl.in
E- Mail weaveco@redil.com
Website www.weaveco.com
Grams 'Kanji weave', Koodali
Bankers Kanpur District Co-op Bank
State Bank of India
State Bank of Travancore
Dept. of Co-operative Society,
Asst. Registrar Office,
Kannur
(TABLE 3.1)

30
 CHAPTER-IV

ANALYSIS OF PRODUCTION DEPARTMENT

31
 PRODUCTION DEPARTMENT

Among all the functional areas of management, production is considered as an

essential in any type of industrial organization. Production is the process by which raw
materials and other inputs are converted into finished goods. It means generation of goods or
services to safely the customer's needs through chemical or mechanical processing.
Production is an activity through which the form utility is either enhanced or created.

The other word synonymously used with production is manufacturing. Manufacturing is

understood to the process of producing only tangible goods, whereas production includes
creation of both tangible goods as well as intangible services.

According to H Harding “production management is considered with those processes

which convert the input into output”. The inputs are various resources like raw materials,
men, machines, methods, etc. And the outputs are goods and services".

According to E.S. Buff, "production management deals with decision making related to
production process. So that resulting goods or service is produced according to specification,
in amount and by the schedule demanded and at minimum cost".

The production department is normally under a production manager. He assists and

supervises production functions. The production manager is the co-ordination link between
the production department and the society. Production department must work in co -
ordination with planning as well as that both of the production target and as estimate by the
objectives are achieved.

The production department maintains the progress of different departments in the

KWCS. The production manager has the responsibility to co-ordinate the availability of raw
materials, labors, machines etc. And also forecast any possible delays which could affect
the production. The efficient working of the production department can prevent delays
before they arise and thereby ensuring maximum utilization of production capacity.

32
 After receiving orders from the production supervisor, the Dyeing Master starts the
sample dyeing. The production supervisor will verify the sample fabrics and send this sample
to customers for colour approval. The bulk production starts only after approving the sample
by the customers. The time taken to complete the work is next concern, which is the
production of each work should be complete within the delivery date given by the customers.

The main raw materials used in the production are:

• Yarn

• Dyes

• Chemicals

• Accessories

The KWCS purchase these raw materials from Government agencies, National
Handloom Development Corporation (NHDC) and also purchase materials from private
agencies. At the time of purchases from NHDC, they provide different subsidies and
purchase of raw materials should be either in cash or credit basis.

Responsibilities of the Production Department

• Ensure high quality

• Reduce wastage

• Ensure reliability in production

• To create flexibility

• Timely production

33
Plant and Machines in KWCS

• Equipped with modern processing facilities to dye colour and reactive dyes with
capacity of 120 bundles/day.

• Working handloom of various width, capable of producing 1800 mtrs/day and 5

special looms for silk.

Stitching unit consisting of modern sewing machines

Table:5.1

SI. No Dye House Weaving Dispatch Others

Department Department
1 Steam Boiler Electrical Fabrics Rolling Water Pump 4 nos
Winding Machine
Machine
2 Feed Pump for Boiler Electric Generator
Hard Warping Strapping
Machine Machine
3 Hydro Extractor - 2 Electrical Platform Balance
numbers Warping
Machine
4 Electric Balance 2 Beaming Machine
numbers
5 Looms
Weighing Balance 2
numbers
6 Drying Chamber
7 Paramount
Colour Matching

Apart from in house capacities, the society got associate manufacturing facilities through
dedicate suppliers to meet the requirement of customers.

PRODUCTION PROCESSES IN KWCS

34
The main production processes in KWCS are given below:

BOILING:

Boiling is the first step in the production process. It is done for removing the imparities
present in the yarn used for bleaching and dyeing. For the boiling process they use wood as
fuel. The processed yarn is bleached using bleaching powder and hydrogen peroxide
according to the requirement.

DYEING:

Dyeing is the process of impregnating the fiber, yarn or fabric with the dyestuff Dyeing
can be done on the yarn, fiber or fabric. It is the method by which colour is applied to the
fabric. Usually they are dyeing the material on the yarn stage.

WINDING:

Winding converts the package of the hank yarn is wounded on the pirn (small
bobbin used in handloom weaving) for preparing the weft. It is done manually, especially of
ladies are engaged in this work.

WARPING:

Warping is the preparatory stage for weaving, which prepares the yarn for weaving.
Cones of yarn are created on to a machine and winding about 500 to 700 threads produce a
sheet of yarn on beam together.

WEAVING:

Weaving is interlacing of vertical yarn (warp) and horizontal yarn (weft). Depending on
the type of the weave, warp sheet is divided and lifted.

Weft yarn is carried across in a pirn help in a shuttle. This is the basis weaving process. The
shuttle is thrown from one end of the wrap sheet to another end by hand.

35
QUALITY INSPECTION:

Quality of the product is thoroughly checked by trained and qualified employees. The
inspection is carried out various stage such as porches of raw materials, during manufacturing
process and final stage to asserts the status of the product for acceptance or otherwise.

CUTTING AND SEWING:

The made-ups are then stitched at the society. Styles are followed in precision with
great care given to dealing in each and made-up items. This unit has a workforce of about 45.

SCOURING:

RECEIPT OF GRAY IN BOILING DEPARTMENT

• Receive the yarn from the godown against the work order and ensure the count identity.

• Receive the bales and check the contents for number of bundles, count the labels

PREPARATION OF GRAY YARNS

• Open the bundles, separate the knots.

• Prepare knot chain count by number of knots (mill wise).

• Identify the different count chain by number of knots/chain.

SCOUR BATCH PREPARATION

• Prepare the chemical bath as per the recipe as approved by production in-charge.

• Mix thoroughly with constant stirring to ensure proper dispersion of the chemical.

• Filter the liquor to remove the un-dissolved particles.

• Add required quantity of water as per the

KIER BOILING

• Wash the kier thoroughly.

36
 • Fill required quantity of water as per the recipe approved by the production in-
charge.

• d the chemical solution prepared earlier to boil.

• Heat the liquor and raise the temperature to boiling.

• Load the yarn chain along the periphery in the kier.

• Keep the yarn in kier for overnight.

• Release the kier solution through the outlet.

• Remove the material from the boiler at the place provided.

• Wash the material by pumping fresh water over it.

• De-link the individual count chains and spread over bamboo stick as per required
knots per stick.

• Neutralize the material in the acid wash tank.

• Wash the material in the consisting soap and soda ash.

• Wash the material in fresh water.

BOBBIN WINDING (MACHINE WINDING)

FOR BOBBIN WINDERS

• Check the tag attached with the yarn bundle to ensure the allotted count and
colour/shade.
• Dress the knot & mount the yarn on swift uniformly to avoid any entanglement and to
ensure smoothing winding.
• Keep the hands clean and dry while winding the bobbin.
• raw the leading thread from the hank wound on the empty bobbin.
• Insert the bobbin in the spindle.
• Mount the bobbin on the winding M/c.
• In case of breakage, join the ends by weavers that the yarn build up does not exceed
the height of the flanges.
• Store the button lot-wise in clean bags with identification.

37
 • Keep the swift and spindle free from fluffs & dirt.

PEROXIDE BLEACHING

RECEIPT AND PREPARATION OF SCOURED YARN

• Check the scoured yarn received for count and quantity against
bleaching/dyeing work order.

• Store the yarn count wise in the allotted place.

• Ensure the storing place is free from all sorts of dirt.

BLEACHING LIQUOR PREPARATION

• Wash the bleaching tank thoroughly with fresh water.

• Prepare bleaching tank by pouring water and required quantity of hydrogen

peroxide liquor and stabilizer soda and caustic soda.

BLEACHING OPERATION

• Heat the liquor to boiling temperature.

• Immerse the material thoroughly in the bleaching tank for required time.
• Rotate the material from top to bottom for at-least 3 times at intervals.
• Take out material, hang it on the stands for required time.
• Wash the material thoroughly with fresh water in the washing tank.
• Hydro extracts the material.
• Prepare fresh bleaching tank for each day.

OPTICAL WHITENING

• Prepare the solution by thoroughly dissolving the required quantity of whitening agent
in the water.

38
 • Immerse the bleached yarn meant for optical whitening in the solution and rotate it
from top to bottom for at least 3 to 4 times.
• Hang it on the stands for about 15 minutes and then get it hydro extracted.
• Take out one knot at random and get it approved from the supervisor (for approved
sample comparison).
• Dry the yarn knots by hanging on the bamboo stick and identify the same.

DYEING

RECEIPT OF YARN

• Verify the yarn received for count and quantity according to dyeing work order.
• Store the yarn count wise in the allotted place.
• Spread the yarn on bamboo rods at the rate of about knots per rod admissible for
different counts.
• Clean the rods before use

PREPARATION OF DYE BATH

• Wear gloves before carrying out the work.

• Weigh the required quantity of dyes and chemicals as per the recipe given by the
supervisor.

• Ensure the correctness of the balance before use (set zero error).

• Dissolve dyestuff with little water and soap.

• Add hot water at the temperature recommended.

• Add chemicals in the dye liquor prepared.

• Stir the solution thoroughly till smooth dispersion obtained.

• Sieve the dye solution, if necessary.

PREPARATION OF DYE TANK

• Select dye tank as per shade and tone.

39
 • Wash the tank with fresh water thoroughly.
• Prepare dye solution in the dye tank by adding required quantity of water to the
solution prepared.

DYEING PROCESS

 Gradually release in steam to bring the temperature of dye solution up-to required
level for hot bath dyeing.
 Squeeze the scoured/bleached yarn before putting into the dye baths.
 Immerse the yarn thoroughly in the dye tank, for the specified period mentioned in the
recipe.
 Rotate the yarn from top to bottom for at-least 4 times.
 Take care to avoid splashing of dye liquor to the adjacent tank.
 Monitor and maintain the temperature as per the standard recipe card.
 After the stipulated duration mentioned in the recipe, take out one knot at random and
after washing and drying produce it to the supervisor for shade matching.
 If approved take out the dyed material and hang it on the rod for
oxidation for about 20 minutes.

 Wash the dyed yarn with soap solution in "soaping tank" as per the
dyeing work order.

 Wash the material in "washing tank" thoroughly with fresh water.

 Perform the washing as per the dye order in-case of special washing
process.

 Identify each bundle with count, colour, shade number & quantity.

 Store the yarn with proper identification

VERTICAL WARPING

40
  Refer Warper's card regarding design, pattern of total no. of ends,
sequences and no. of colour. Threads of the desired counts, length of
warp & pattern of repeats.

 Arrange the bobbin on the creel through comber in accordance with the
pattern requirements.

 Draw the ends from the creels through the comber in accordance with
the pattern requirements.

 Tie the starting ends of the yarn on the starting pegs at the top of the
warper's frame.

 Prepare the leasing arrangement of the wrap and drew the ultimate ends
over and under the leasing pegs at the top of warping frame.

 Rotate the warping frame maintaining the uniform tension and wind the
warp on the warping frame from top to bottom passing warp on either
side of the leasing pegs according to repeat of-the design at the bottom
also.

 Ensure the required length of the warp to be wounded by the no. of

rotations given.

 Repeats above operation until the required no. of ends are wound on the warping
frame.

 Insert a leasing twines in the space formed by the leasing pegs and unwind the warp
and bundle it into rope form.
 Attach identification tag along with the ready warp in the rope form for identification
purpose after mentioning warper's identity, date of warping and length of warp
wound.

BEAMING

41
 REFER WARPER'S CARD FOR DESIGN, PATTERN OF WARP & WIDTH
OF FABRIC REQUIRED

 Select the weaver's beam according to the width of the warp.

 Fasten the warp on the wooden rod and place it on weaver's beam.
 Select a beaming comb of compatible size with that of the weaver's beam.
 Carefully select the ends of the warp as per design and make it into convenient groups
of ends.
 Insert 15 to 20 sets of such selected groups of ends in the dent of beaming comb.
 While drawing through the dents, take care to leave out convenient number of dents
blank so as to spread the entire warp across the full width of the weaver's beam.
 Rotate the weaver's beam firmly and steadily, to wind the yarn on the weaver's beam.
 Take care to avoid winding of warps concentrated near the flanges.
 Ensure even winding tension through the width of the warp sheet.
 At the end of the warping, insert the leasing rods and remove the leasing twines.

DRAWING AND DENTING

FOR DRAWER DRAWING

 Ensuring the heald for the correct length and type specified.

 Stretching the warp ends to felicitate selection of the correct thread drawing into
heald wires and latter through the read.
 Draw the ends as per the drawing order given by the supervisor.
 Check the number of the heald wires per shaft form the draft.
 Ensure equal number of heald wires on the either side of the warp.
 Ensure uniform harness level in-case of jacquard loom.

DENTING

42
  Ensure the reed for count & type.
 Clean the reed using metal brush to remove foreign matters and use light oil to
remove the rust.
 Compare the width of the warp and length of reed.
 Leave equal space of reed on the both sides of warp.
 Insert the hook through the middle of the dent and pull the hook
 straight backward to avoid any damage to dent.
PIECHING UP

• In the case of some design being continued, piecing process may be adopted

PIRN WINDING
 Identify the pieces meant for the embroidery as per the embroidery register.
 Verify the design, measurement with the approved sample given.
 Verify the thread received from the stores for the correct shade number.
 Ensure that the right design has been loaded in the machine.
 Ensure correct design is marked on the piece for the manual operating machine.
 Ensure correct thread tension.
 Operate the machine and get the number of times planned.
 In case of discrepancy, inform the supervisor immediately.
 Keep the operating area neat and clean.

WEAVING FOR WEAVER

 Ensure that the weaving id carried out according to design requirements as per the
approved sample.
 Take care to avoid the following faults:
o Warp and weft float,
o Reed marks
o Missing and wrong drawn ends.
o In case of end breakage join the ends by weaver's knot,
o Keep the shuttle roller free from waste. /
o Handle shuttle carefully to avoid damage to the reed,
APATTERN MAKING

43
Pattern maker to carefully examine the stitch of the garments and made-ups sent by the
customer and ensure the following while drafting the patterns
• Identify the no. of patterns required for made up/garments.
• Prepare patterns for individual size for production.
• Prepare pattern count (no. of pattern sections) according to style.
• Seam allowance should be based on style and the type of fixtures on sewing
during manufacturing.
• Identify the pattern by its style, number, customer's name and name of part,
pattern count, date of preparation and mention of its status "PRODUCTION" or
"SAMPLE".

CUTTING
CUTTING BEDDING ITEMS
• Spread fabrics on the cutting table according to the measurement.
• Check the fabrics for any defect.
• Align the fabrics on one side of the selvedge.
• Cut the fabrics manually according to the size & requirements.
• Identify the bundle with name of the product and size.
• Ensure operational cleaning.

CUSHION COVERS/BOLSTER

 Spread the fabric according to size of the cushion cover.

 Remove the required quantity of the fabric for piping to avoid shade variation (if
required).
 Mark the measurement in the fabrics.
 Cut the fabric according to size.
 Bundle the pieces together with the piping fabric. Mark
xszzzzzzzthe bundle with roll nos.
 Identify the bundle with the name of the product & size.
MADE-UPS (M/C CUTTING)

44
 Only on the approval of the supervisor the cutting operation is carried out in the
following manner:
• Ensure the position of the blade, its sharpness and the reciprocating speed of the
machine.
• Cut the stack of fabric by propelling the cutting machine/instrument on the marking
line with precision.
• Exercise due care during cutting to avoid defective cutting.
• Remove the cut scrap regularly.
• Tie the cut into a bundle with proper identification.
PROCESS FLOW CHART:WEAVING & PRODUCT MEASUREMENT

YARN

BOBBIN WINDING

CREELING

VERFICATION

PIRN WINDING
BARAMING

DRAWING

(FIG:5.1)

WEAVING

FIRST PIECE
APPROVAL

INSPECTION
45
PACKING
MADE UPS
 PROCESS FLOW CHART-DYEING

BALE OPENIGN

YARN CHAINING

SCOURING

WASHING

ACID WASHING BLEACHING

SCOURING
WASHING

(FIGURE 5.5
WASH OPTICAL
BRIGHTENING
SQUEEZING

STRECHING

DYEING

OXIDATION

WASHING

SQUEEZING

SHADE APPROVAL DRYING

46
PRODUCTION PROCESS IN KWCS

BOILING

DYEING

WINDING

WARPING

WEAVING

QUALITY INSPECTION

CUTTING & SEWING

47
 (Fig 5.3)

STRUCTURE OF PRODUCTION DEPARTMENT

CHIEF EXECUTIVE

PRODUCTION MANAGER

DYEING MASTER WEAVING MASTER

ASST. DYEING MASTER ASST.WEAVING MASTER

WORKERS WORKERS

WORKERS WORKERS

48
PRODUCTION PROCESS

49
 CHAPTER-V

EFFECTIVENESS OF PRODUCTION AN ANALYSIS

50
 TABLE 6.1

NUMBER OF WORKERS AS PER GENDER (in %)

MALE FEMALE

25 75

(SOURCE: Questionnaire)

GRAPHIVAL REPRESENTATION NUMBER OF WORKERS AS PER

GENDER

25

MALE
FEMALE

75

(Chart 6.1)

75% of the workers in the company are females

51
 TABLE NO 6.3
NO OF WORKERS AS PER THE POST HELD
POST HELD NO OF WORKERS
DYER 2
WEAVER 25
TAILOR 6
OTHERS 17
TOTAL 50
[Source: Questionnaire]

GRAPHICAL REPRESENTATION

NUMBER OF WORKERS IN KWCS AS PER POST HELD

NO OF WORKERS AS PER POST HELD

50

40

30
NO OF WORKERS
20

10

0
DYER WEAVER TAILOR OTHERS TOTAL

(Chart 6.3)

Most of the people working in the KWCS are weavers and the least is dyers

52
.

TABLE 6.4
MAJOR INSTURMENTATS USED IN THE PRODUCTION
DEPARTMENT
INSTRUMENTS PERCENTAGE
MAKKAM 60
CHAKKA 25
SEWING MACHINE 10
OTHERS 5
TOTAL 100

GRAPHICAL REPRESENTATION

MAJOR INSTURMENTS USED IN THE PRODUCTION

DEPARTMENT

MAKKAM
CHARKKA
SEWING MACHINE
OTHERS

53
 (Chart 6.4)

Makkam is the most commonly using equipment in KWC

TABLE 6.7
SHOWING THE READINESS TO ACCEPT FURTHER TRAINING AND
RECENT TECHNOLOGY
PARTICULARS YES NO
Acceptance of further 20 80
training
Acceptance of recent 80 20
technologies

80

70

60

50 Acceptance of further
training
40
Acceptance of recent
technologies
30

20

10

0
YES NO

(Chart 6.7)

54
Only 20% are ready to accept further training but 80% are read

TABLE 6.9
EARNINGS OF THE WORKES [in a day: in rupee]
AMOUNT NO OF WOKERS
0-50 0
50-100 4
100-150 28
Above 150 18
TOTAL 50

EARNINGS OF THE WORKERS [in a day: in rupee]

EARNINGS OF THE WORKERS

50

45

40

35

30

25 NO OF WOKERS

20

15

10

0
0-50 50-100 100-150 Above 150 TOTAL

(Chart 6.9)

The earning of the most of the workers ranges between 100-150 and no one earns
between 0-50.

55
 TABLE 6.10
DURATION TAKEN BY THE WOKERS TO COMPLETE A WORK ORDER
DURATION NO OF DAYS
Below 10 13
10-15 2
15-20 5
20-25 5
25-30 10
Above 30 15
TOTAL 50
DURATION TAKEN BY THE WOKERS TO COMPLETE A WORK ORDER

DURATION TAKEN BY THE WOKERS TO COMPELTE A

WORK ORDER

15

10

NO OF DAYS
5

0
Below 15-Oct 15-20 20-25 25-30 Above
10 30

(Chart 6.10)

Most of the workers require more than 30 days to complete an order

56
 TABLE 6.11
PRODUCITON EFFICIENY
NO OF EMPLOYEES WORKING IN VARIOUS DEPARTMENTS

PARTICULARS NO OF EMPLOYEES
Office staff 15
Dyeing 16
Weaving 232
Winding 80
Packing 10
Sales 8
Designing 2
Stitching 12
Total 375
GRAPHS FOR MEASUIRING PRODUCITON EFFICIENY

NO OF EMPLOYEES WOEKIRNG IN VARIOUS DEPARTMENTS

GRAPHS FOR MEASUIRING PRODUCITON EFFICIENY

NO OF EMPLOYEES WORKING IN VARIOUS DEPARTMENTS

400

300
NO OF
EMPLOYEES
200

100

(Chart 6.12)

57
 TABLE 6.13

PURCHASE OF RAW MATERIALS IN 2014

[Monthly wise analysis in kg]

Raw materials
Month
Yarn Dyes & chemicals Accessories
January 4471 233 332
February 4871 1564
March 3307
April 3128 749 335
May 5667 1634
June 5538 1913
July 5630 1946 15
August 2691 1840
September 1504 501
October 1334 1546
November 3238 1121
December 8616 1633

9000
8000
7000
6000
5000
4000
Yarn
3000
2000 Dyes and Chemicals
1000 Accessories
0
January
February
March
April
May
June
July
August
September
October
November
December

(Chart 6.13)

58
 Similar to 2013 in this year also yarn is purchased in a large volume than all other raw
materials and least one purchased is the accessories itself.

TABLE 6.14
PURCHASE OF RAW MATERIALS IN 2015
[Monthly wise analysis in kg]

Raw materials
Month Yarn Dyes & chemicals Accessories [zip]
January 5543 805
February 1605 349
March 8464 18 517
April 5065 1779 620
May 11762 2201 548
June 4416 1540
July 1748 1450 1939
August 2530 946
September3 5180 1157 2485
October 40098 79 2260
November
December

PURCHASE OF RAW MATERIALS IN

2015
50000
40000
30000
Raw materials
20000
10000
0
July

October
August
April

September

November
Month
January

May
June

December
March
February

(Chart 6.14)

Here also yarn is purchased in a higher volume and the accessories the least

59
DETAILS SHOWING PRODUCTION & SALES, 2017 IN KWCS

[Table-6.16]

Production Sales
Month Products
Qty(in Mtr) Value(in Rs) Qty(in Mtr) Value(in Rs)

Jan 14 Furnishing Fabrics 4263.00 852600.00 3986.00 896850.00

Bed sheets 5636.00 1059568.00 3256.00 651200.00

Lungies 1826.00 301290.00 898.00 166130.00

Shirting 4326.00 1016610.00 936.00 234000.00

Dothies 3636.00 654480.00 653.00 130600.00

Feb 14 Furnishing Fabrics 5231.00 941580.00 4563.00 912600.00

Bed sheets 4123.00 742140.00 1256.00 251200.00

Lungies 1423.00 256140.00 963.00 192600.00

Shirting 4562.00 821160.00 489.00 97800.00

Dothies 3965.00 713700.00 1100.00 220000.00

Mar 14 Furnishing Fabrics 3969.00 714420.00 2989.00 597800.00

Bed sheets 5263.00 947340.00 2221.00 444200.00

Lungies 1365.00 245700.00 896.00 179200.00

Shirting 5231.00 941580.00 636.00 127200.00

Dothies 4263.00 767340.00 896.00 179200.00

Apr 14 Furnishing Fabrics 3969.00 714420.00 3256.00 651200.00

Bed sheets 6233.00 1121940.00 6100.00 1220000.00

60
 Lungies 1563.00 281340.00 4896.00 979200.00

Shirting 6235.00 1122300.00 8121.00 1624200.00

Dothies 6212.00 1118160.00 6398.00 1279600.00

May 14 Furnishing Fabrics 4856.00 874080.00 3698.00 739600.00

Bed sheets 6363.00 1145340.00 936.00 187200.00

Lungies 1726.00 310680.00 1126.00 225200.00

Shirting 6235.00 1122300.00 1135.00 227000.00

Dothies 5231.00 941580.00 963.00 192600.00

Jun 14 Furnishing Fabrics 5236.00 942480.00 3798.00 759600.00

Bed sheets 7563.00 1361340.00 1425.00 285000.00

Lungies 1563.00 281340.00 725.00 145000.00

Shirting 4256.00 766080.00 4635.00 927000.00

Dothies 4989.00 898020.00 1126.00 225200.00

Jul 14 Furnishing Fabrics 3236.00 582480.00 2989.00 597800.00

Bed sheets 6253.00 1125540.00 1125.00 225000.00

Lungies 1725.00 310500.00 1322.00 264400.00

Shirting 5236.00 942480.00 5263.00 1052600.00

Dothies 3963.00 713340.00 1456.00 291200.00

Furnishing 4256.00 766080.00 3789.00 757800.00

Fabrics

Aug Bed sheets 6396.00 1151280.00 7125.00 1425000.00

14 Lungies 1936.00 348480.00 3125.00 625000.00

Shirting 6231.00 1121580.00 6236.00 1247200.00

Dothies 4231.00 761580.00 5141.00 1028200.00

61
 Furnishing 3956.00 712080.00 3796.00 759200.00

Sep 14 Fabrics

Bed sheets 7265.00 1307700.00 6369.00 1273800.00

Lungies 2123.00 382140.00 2963.00 592600.00

Shirting 5365.00 965700.00 6478.00 1295600.00

Dothies 6121.00 1101780.00 4210.00 842000.00

Furnishing 3896.00 701280.00 3798.00 759600.00

Fabrics

Oct Bed sheets 6369.00 1146420.00 986.00 197200.00

14 Lungies 2111.00 379980.00 563.00 112600.00

Shirting 6235.00 1122300.00 696.00 139200.00

Dothies 4896.00 881280.00 896.00 179200.00

Furnishing 4256.00 766080.00 2989.00 597800.00

Fabrics

Bed sheets 7250.00 1305000.00 1136.00 227200.00

Nov Lungies 1635.00 294300.00 963.00 192600.00

14 Shirting 5263.00 947340.00 1126.00 225200.00

Dothies 4256.00 766080.00 687.00 137400.00

Furnishing - - - -

Fabrics

Dec Bed sheets - - - -

14 Lungies - - - -

Shirting - - - -

Dothies - - - -

TOTAL 245772.00 44579848.00 149303.00 29993580.00

62
 DETILS SHOWING PRODUCTION AND SALES IN
2018KWCS
Table 6.17

Qty(in Mtr) Value(in Rs-) Qty(in Mtr) Value(in Rs-

;
furnishing Fabrics 3916.00 783200.00 4001.00 900225.00

3edsheets 6216.00 1168608.00 5968.00 1193600.00

Lungies 1736.00 286440.00 1126.00 208310.00

Shirting 3269.00 768215.00 1036.00 259000.00

Jan-15 Dothies 2936.00 528480.00 778.00 155600.00

-furnishings Fabrics 4916.00 884880.00 3986.00 797200.00

Bedsheets 5213.00 938340.00 1356.00 271200.00

Lungies 1396.00 251280.00 798.00 159600.00

Shirting 4963.00 893340.00 376.00 75200.00

Feb-15 Dothies 2936.00 528480.00 1250.00 250000.00

:
urnishing Fabrics 3698.00 665640.00 3002.00 600400.00

Bedsheets 5623.00 1012140.00 1989.00 397800.00

.ungies 1296.00 233280.00 1026.00 205200.00

Shirting 4936.00 888480.00 986.00 197200.00

Mar-15 Dothies 3965.00 713700.00 796.00 159200.00

Furnishing Fabrics 4125.00 742500.00 4890.00 978000.00

Bedsheets 5936.00 1068480.00 7200.00 1440000.00

Lungies 1469.00 264420.00 4896.00 979200.00

Shirting 6136.00 1104480.00 7986.00 1597200.00

Apr-15 Dothies 5936.00 1068480.00 5968.00 1193600.00

Furnishing Fabrics 4926.00 886680.00 5300.00 1060000.00

Bedsheets 5936.00 1068480.00 1026.00 205200.00

Lungies 1596.00 287280.00 1326.00 26520. 00

63
 Shirting 6136.00 1104480.00 2350.00 470000.00

May-15 Dothies 5623.00 1012140.00 1011.00 202200.00

Furnishing Fabrics 4989.00 898020.00 4250.00 850000.00

Bedsheets 6896.00 1241280.00 1856.00 371200.00

Lungies 1659.00 298620.00 669.00 133800.00

Shirting 4656.00 838080.00 3968.00 793600.00

Jun-15 Dothies 4936.00 888480.00 1236.00 247200.00

Furnishing Fabrics 4965.00 893700.00 2989.00 597800.00

Bedsheets 5963.00 1073340.00 1125.00 225000.00

Lungies 1689.00 304020.00 1322.00 264400.00

Shirting 5632.00 1013760.00 5263.00 1052600.00

Jul-15 Dothies 4126.00 742680.00 1456.00 291200.00

Furnishing Fabrics 3969.00 714420.00 3789.00 757800.00

Bedsheets 6256.00 1126080.00 7125.00 1425000.00

Lungies 2011.00 361980.00 3125.00 62500" 0C

Shirting 5989.00 1078020.00 6236.00 1247200.00

Aug-15 Dothies 3965.00 713700 00 5141.00 1028200.00

Furnishing Fabrics 4122.00 741960.00 3925.00 785000.00

Bedsheets 6936.00 1248480.00 5256.00 1051200.00

Lungies 2896.00 521280.00 3211.00 642200.00

Shirting 6126.00 1102680.00 5987.00 1197400.00

Sep-15 Dothies 5698.00 1025640.00 3896.00 779200.00

Furnishing Fabrics 5236.00 942480.00 3124.00 624800.00

Bedsheets 6212.00 1118160.00 689.00 137800.00

Lungies 3008.00 541440.00 569.00 113800.00

Shirting 5696.00 1025280.00 621.00 124200.00

Oct-15 Dothies 3989.00 718020.00 889.00 177800.00

64
 Furnishing Fabrics 5623.0 1012140.0 2656.00 531200.00

Bedsheets 7360.0 1324800.0 998.00 199600.00

Lungies 1863.0 335340.0 758.0 151600.00

Shirting 6212.0 1118160.0 912.0 182400.00

Nov-15 Dothies 4365.0 785700.0 523.0 104600.00

Furnishing Fabrics 4653.2 837576.0 2876.0 575200.00

Bedsheets 6856.5 1234170.0 3265.0 653000.00

Lungies 1625.0 292500.0 896.0 179200.00

Shirting 4265.0 767700.0 1652.0 330400.00

Dec-15 Dothies 3256.0 586080.0 1986 0 397200.00

268532.70 48617689.00 164666.00 33068135.00

65
 TABLE 6.18
TOTAL PRODUCTION OF KWCS IN 2016-18
YEAR PRODUCTION
QTY [in mtr] VALUE [in rupees]
2016 262276.90 4753971.00
2017 245772.00 44579848.00
2018 268532.70 48617689.00
[source: Official records]

TOTAL PRODUCTION OF KWCS IN 2016-18

50000000
45000000
40000000
35000000 YEAR
30000000
25000000 PRODUCTION QTY [in mmr]

20000000
PRODUCTION VALUE [in
15000000 rupees]
10000000
5000000
0
1 2 3 4

(Chart 6.15)

66
 SWOT ANALYSIS OF KWCS
STRENGTH
❖ Good brand name
❖ Better and experienced workforce
❖ Good quality
❖ Better working condition
❖ Good management-employee relationship

WEAKNESS

❖ Present only in Kannur district

❖ Less promotional activities
❖ Less market share

OPPORTUNITIES
❖ Implementation of technology
❖ Products expansion
❖ Scope of international marketing

THREATS
❖ Lack of proper advertisements
❖ Lack of proper government's intervention
❖ Existence of competitors

67
 CHAPTER VI

FINDINGS AND SUGGESTIONS

68
 FINDINGS AND SUGGESTIONS

 Production as per demand.

 High concentration on local market.
 Lack of concentration on international marketing.
 75% of the people are not aware of KWCS due to lack of advertisements.
 Production and utilization of raw-materials are severely affected by the existing
weather condition.
 In the factory 80% of the cost of production is by the raw-material cost.
 Price fluctuations of raw-materials are affecting the production severely.
 The production and sales of the company is gradually decreasing (data as per 2013-
15).
 The company uses more man power than mechanical power.
 The company has a good experienced & quality workforce.
 Most of the workers are between the age of 35 & 60. It lacks the intervention of the
young and energetic workers.
 Company provides good working condition to its employees.
 Traditional technologies and working methods are highly' using in the factory.
 Company enjoys high sales turn over in festival seasons like Onam, Chirstmas etc.
 Recently the company opened a retail show room nearby the factory to attract local
customers.

 SUGGESTIONS

 The marketing department can adopt recent trends of marketing that leads to customer
satisfaction quickly.
 The company may provide more advertisements about the products through T.V and
other medias to create greater consumer awareness of the products.
 The company can markets through Kudumbasree and Ayalkoottam, so that the sale of
the product can be increased.
 It is better for the company to create necessary arrangements to make their products
available anywhere.
 The company can take rigid sales forecasting methods for reducing cost.

69
  Improve the efficiency of marketing department by new techniques of marketing with
attracting advertisements.
 Improve brand image in local area.
 Increase the utilization of production capacity.
 It should appoint very efficient agency to supply products.
 Proper H.R management should be adopted.
 Systematic and scientific training should be provided to the employees to increase
productivity.
 Proper inventory control should be bought up by the firms in order to control
production cost.
 Maximize share holders wealth and use finance function in an effective manner.
 It is better for the company to increase production capacity up-to a desired level.

CONCLUSION:

In this competitive world unless our industries adopt modern technologies and produce
the high quality products with low cost, it is difficult to survive.

The textile produced in KWCS is of excellent quality. But the company cannot produce
sufficient quality of product to supply all over the world. KWCS is a co-operative firm with
wide range of alternative product works. It has a good reputation in all over the areas of
operation. It is in the graving stage with strong operation set up and professional
management.

The major defect of the society is it is unable to produce more if it receives orders from
merchant exporters as a result its total production and sales decreases gradually. But, the
interesting factor is that it is able to earn more profit through this. So, it reduce its production
and sales to the local market. The society experience the same situation from 2013-2015
[Table 15-16 show the same]. However, a large majority of the persons have good opinion

70
regarding KWCS and its products. All customers are satisfied with the price and quality of
the society's products.

The study was conducted to measure the overall performance of the production
department. I have collected necessary information from my observations and personal
contacts with the workers and officials. The overall performance of the production
department is satisfactory. Improvement has to be made in certain areas of the company to
sustain in the forth coming years.

I tried my level best to give clear and real picture about organization's production
performance. In addition to this I have found some problems and suggested solutions which I
felt relevant.I hereby declare that my study at "KANHIRODE Co - operative Society P & S
Ltd." was done in a satisfied manner.

BIBLIOGRAPHY

1. vvww.bef.org/industry/textiles.aspx.

2. www.fiberzfashion.com/industry..../an- an....

3. http. www.maps-india.com/overview/textile and sugar.html

4. (2015) Reports and published materials in the company

5. Textile industries.(n.d). Retrieved from www.textileindustries.

71