ecutive Summary Gulshan Textiles is located in Tibba Sultan Pur with capacity of 6000 spindles.

This mill started its production in 1980 and is owned by Gulistan Group, which also owns Kiwi Shoe Polish located in Karachi. Head Office of Gulistan Group is located in Lahore. I visited Gulshan Textiles two times for my report and was always warmly welcomed by their management and employees. All machinery installed in the mill is American. Plans and strategies are made in the head Office. Raw materials purchase decision is also made in the Head Office. Employees work in three shifts, whereas these are both permanent and on daily wages. The mills units is supported by different facilities as canteen, store room, laboratory, godown, and many others. The production process is divided into two sections: Refining section Finishing section   In Refining Section, Blow Room and Carding Department are present, whereas Finishing Section consists of Drawing, Roving, Spinning and Machine Cone, and then finally store Room. Final product of this spinning unit is in form of yarn, which is both locally and internally purchased by the customers. Quality checks prevail in all three stages, when it is in raw material, work-inprocess and finished goods form. For this purpose, a laboratory with advanced machines is present. Introduction of the Company Gulshan Group is basically a group of spinning units scattered throughout the country. This is one of the big units, which is providing their services for the industrial sector in Pakistan from last several years. Their services and works are not forgettable. There are 12 units. The famous ones are:

. The company name is renowned all over the Pakistan due to their best quality. having maximum capacity of producing 240 bags daily. is automated. Company mission statement As all others companies. company has also their mission statement. Gulshan Textile Mill was started in 1980 and is working since then. It has almost 1000 employees working 24 hours a day. The Head Office of GTM is located in Lahore while the unit is located in Tibba Sultan Pur. seven days a week. The mill runs throughout the year except 10th of Moharram. on time delivery and continuous improvement. which clearly tell that why company is in this business and what are their beliefs.Tibba Sultan Pur Rohri Lahore Samma Satta They are under the name of Gulshan and Gulistan. They always keep their customers demand and their requirement in their mind and emphasize on better to better. which is installed in the mill. Profile of the Company Gulshan Textile Mills Limited is owned by Chaudhry Abdul Shakoor who has vast business in the name of Gulistan Group. The statement is. 2-10 and 10-6 with 300 workers per shift. GTM produces yarn of different counts on demand. The total spindles are 6000. Their products are mostly exported to the European countries and Hong Kong and Singapore. The plant. Local market share is less as compared to export business. Firm manages 3 shifts each of eight hours from 6-2.

Land was very cheaply available because in the cities land is very costly available. Managing Director is Mian Naseer Ahmad. because if it will be in within the city it will create a lot of problems for the organization survives. . from where company can contact with the whole Pakistani markets. The Technical Director is Chaudhry Shakoor and General Manager Chaudhry Nisar Ahmad. Company believes that due to this location they can provide the good services to their customers. then due to communication of different employees union becomes strong problem for management. Transportation is also easily available. This decision was made due to following basic reasons: It was away from city. The labor was easily available and cheap as well. Distribution Distribution is another tool which also effect the company over all performance. The area is surrounded by villages. The unionization of employees is minimum. Location Gulshan Textile Mill is located 80 kms away from the Multan city. That's why company decided to locate the mill out side the city of Multan."We are in this business to provide the customers good quality cotton yarn and fastest and on time delivery service" Organizational Setup The Chairman of Gulshan Textile Mill is Mian Abdul Shakoor. This is because labor on daily and monthly wages is very easily accessible. If the mill would have been installed within premises of city. which belong to any type of industry.

They have their own trucks or they have their contract with the transport agencies for the local delivery purposes.       Gulistan Textile Mill Workers Colony Staff Colony Main Road Gate   Godown Auto Plucker Workshop . Else this. These containers are used for the long routes and for the local services of distribution. which are playing very active role in the filed of distribution. supporting facilities and buildings is provided by top management. for the export purposes company uses the containers for the efficient delivery purposes. company has very effective and efficient distribution system. For this reason. In each containers there are 350 bags are packed. Facility Design & Layout Facility design and physical layout of plant.Company also emphasizes their distribution system. They want to provide their customers on time delivery services. they normally used the truck system. Their physical layout provides maximum utilization of available space by optimizing costs.

Canteen Lab GM Office Store Room Auto Coner Roving Ring Drawing Carding Blow Room Entry             Godown Pipe Support Facilities .

Support facilities are essential for operations. but when . These are: Inventory Materials and Suppliers. The market trend is followed. the price of cotton has a direct impact on the sales forecast. If there are fluctuations in the basic raw material (cotton). When the crop is good then due to market mechanism prices remain stable. Inspection and Quality Control Laboratory Packing Facility Canteen Labor Colony Staff Colony Medical Facility Tube Well Grid Station Cotton Godown Mechanical Workshop Warehouse Forecasting Forecasting methods in GTM revolves around the concept of supply and demand. Similarly.Support facilities are carried out in such a way that the direct operations can function smoothly. The methods used for forecasting are: Judgmental Time series (for purchase of raw material) The panels of experts sit together and discuss the situation and conditions controlling the demand of thread. then sales forecast also changes.

say 30 or 40. Capacity Planning The long-range operational strategy of an organization is expressed in terms of capacity planning. the production capacity reduces because it is more time consuming and vice versa. cotton bales are put into process for refining purposes. The company forecast the demand for the medium term period. Measure of Capacity of GTM The capacity of any spinning unit can be measured by number of spindles installed.cotton prices are higher due to bad crop season then demand of cotton overall is decreased. When the thread is of more count. i. 24 hours a day. The production capacity of GTM is 6. 240 bags are made daily.000 spindles.e. The plan for future is to install a Sui gas power plant to save the lost time due to electricity failures. because of demand of yarn my be fluctuated or price has also effect on the forecasting and it is not possible for forecast the demand for shorter and longer time period. technological innovations. In capacity planning. This section is divided into two departments. Production Process The production process of GTM is divided into two portions: Refining section Finishing section Refining Section In this section.. the factors like market trend. Blow room . They are planning to increase the spindles as well. process innovation and the optional size of plant are important. Capacity Plans at GTM Currently the mill is operating at its full capacity. Each bag is of 100 pounds.

All this is done in carding machine. Without it. then wastage ratio ranges between 15-20%. but it depends on the quality of cotton bales. the remaining impurities must be removed. The waste ratio is about 10%. 12 to 15 Bails are putting in these auto pluckers and avg. then wastage is less. again they open and clean it by hands. The output of the blow room. The temperature of blow room is 850 F (Dry) and 700 C (wet). If cotton is of good quality. Avg. weight of per bail is 160 kg. Carding Stucking Card room Plucking Before the raw stock is converted into yarn. The basic purpose of this section is to firstly warm up the cotton bales. which is . which cause cotton hips. fibers must be disentangled and they must be straightened. The name of these machines is Auto Plucker.   In this section. and if it is of low quality. fly wastes with other wastes are also removed. 75 bails are running and consume daily. which take a 10-12 hours are for performing this process. Percentage of impurities depends on quality of cotton.Carding Blow Room It is also known as warm-up period for cotton. it is impossible to produce fine yarn. Jute is plucked from there. Avg. and then to remove dust and other waste particles from the cotton. is called the input of the carding department. which is lap. End product is like rope. The cotton plucking is carried out by both manually as well as with machines. Second thing is the convey testes which means that bails when come from Auto pluckers.

. Then doubling occurs by twisting two threads. only one sliver is obtained. Special lights are there which check the quality of cotton and yarn and any of them is not according to quality then they withdraw it from lot. where further drafting process and twisting takes place. This is done to get uniformity in the thread and after it.gathered in cans. (pounds). Each can is of 20kg. blending is done in this section. This is the output of card department. drawframe. it is parallel and regular. Roving Final product of drawing is placed on roving or simplex frame. the yarn is twisted to achieve the required fineness. cotton is converted into yarn. thereby producing longer and thinner sliver called roving and process is called the drafting. Number of cans is 8. These cones are final products of the spinning unit.175 lbs. In this section. Finishing Section In this section. Store Room Then these cones are transferred to StoreRoom where they packed. These are called Sliver. Machine Coner or AutoConer Cones are prepared in this section or department. Ring The main purpose of this department is to strengthen the yarn. In this section. The weight of each cone is 4. A carton contains 24 cones. different cans are put and from this. or in other words. which is used for drawing has several pairs of rollers. These cones are then brought to conditioning plant. whereas 350 cartons are taken in one container. Following departments take part in this activity: Drawing In this section. which produces moisture in cotton. This sliver is then again blended with others in the same manner. These rollers pull the staple length-wise over each other.

They divide the yarn into following categories: Thick yarn 1 – 10 count . The mill hires specialized professionals to perform this task. Predicting the nature and impact of innovation places one firm in more competitive position than a firm. Major breakdowns are rare. but it may be somewhat less costly when designed and developed by other ways. Product Planning at Gulshan Textiles The product planning in GTM is carried out by top managerial positions or professionals in their Head Office in Lahore. Operations management functions are currently being successfully implemented by management. Product Strategy GTM is using the mixed product strategies in their production process. except of the fire emergency in blow room back in 2-3 years. Gulshan Textile Mill’s Other Operations GTM has completed its 19 years of success. If the price and order time suits him or not and if figures are hopeful. They negotiate with the buyers. which doesn’t anticipate these evens. product is made. Then according to their command. The requirements are communicated by mill manager to Head Office. Technical Consideration The Gulshan Textile Mill has one technical director who is responsible for checking out technical aspects of production. production is started. following are some other important functions. A product or service designed one way may be costly to products. Yarn of different counts is produced in GTM. Besides.Production Flow Chart Product Planning The competitors and profitability of an organization depends upon design and quality of products and services it produces and on cost of production.

Inventory Management .Coarse yarn 11 – 20 count Medium yarn 21 – 40 count Medium fine yarn 41 – 80 count Fine yarn 81 and above Workforce Strategy GTM has daily wage laborers as well as monthly paid workers. when cotton is produced the firm buys more and in other periods. the purchase is according to the demand. They hiring and firing is common in GTM. When the firm is not earning any profit. The safety stock level would be the reorder point because the 10. They order period wise in any size order. then mostly idle labor is fired to reduce cost. Reorder Point The GTM as such has no specific reorder point. If finances allow then more cotton is stored. the firm is facing problems financially because of bad economic conditions of country and cotton decline so labor is fired. The raw materials are purchased on continuous base whenever the need arises.000 bales for smooth and continuous production. Generally in season like October November. Order Size No specific formula is used for computing order size. For last three years. Material Requirement Planning Safety Stock of GTM GTM maintains a safety stock of raw material of 10. The company has stock of bales to fulfil the requirements and daily spinning capacity.000 bales to be kept. Lead Time The lead-time of GTM is one month.

is kept in cotton godown attached to the mill where there is strict control on raw material and all possible mishandling and theft are minimized. The trollers and tractors are hired for this purpose. once the raw material is put in process then finished product will be taken out without keeping it in processing. Company has their own godowns where raw material is stocked. Only the small amount of processed cotton and polyester is kept when it has to be transferred from one department to another. Transportation The cotton or textile mills all over the country generally use the road transport for delivery of goods. When the goods are to be exported then big trollers (NLC) are hired to take goods at port and if thread is to be sent in local market. then usual trucks of relatively . Work-in-Process The spinning mills usually don’t need work-in-process inventory because it is a continuous process. it is issued to them with the signature of General Manager on the written application of cotton clerk. The warehouse of buyer is also used to reduce the cost. The raw material that is cotton. The raw material is purchased during the cotton season by making sales forecast from the past year experience. but it is transferred daily so separate mechanism is present for keeping WIP inventory. Finished Goods Inventory The finished goods inventory is kept by the mill because the products are produced daily so finished goods are placed in separate rooms attached with finishing department. where it is kept after packaging and withdrawn according to demand. the three basic types of inventories are: Raw Material Inventory Work-in-process Inventory Finished Goods Inventory Raw Material Inventory 10.In any manufacturing firm. When unit requires a raw material.000 bales of cotton have to be kept as inventory at all times.

oven dries it. but in a day 3 times the G. where decision about purchasing is done. and is checked by moisture meter. For cotton. The quality is checked in every step. Quality Control The quality control techniques and tools of GTM are very efficient.cheaper cost are hired. inspection of different samples coming from different ginning mills is carried out. If it is more than conditioning. There are three basic types of quality control: Raw material Work-in-process Finished goods Quality Assurance of Raw Materials Before purchasing the raw material. The results are sent to the Head Office. following factors are considered: Moisture level Thickness Color of cotton Presselay strength Trash content Staple length Uniformity ratio Short fiber percentage The moisture level is maintained from 8 –10%.M and other technical staff visit the plant and check the overall performance. Quality Assurance of Work-in-Process and Finished Goods . The trucks could be hired at any time and costs are set by agreement previously.

Colorimeter Colorimeter is used to check to color of cotton because when cloth is dyed. It checks uniformity of thread. Every time when new mixing is to be used. The air passes through the fiber and the reading moves.. Uster Classimat It is used to check the fluff of yarn. The elasticity. Micronere Tester Fineness of fiber is measured by this machine. Spectrogram The periodicity is checked through spectrogram.. The weight of finished product is checked in autosoughter .e. The cleaning is judged. The mixing in blow room i. Uster-Testing It checks uniformity of both yarn and sliver. Uster-tenso Rapid It is used to check single yarn say 50cm. How many thick and thin places are present per 1000m. elongation and strength is checked by passing it through machine. i. This test means that how much thread is moved and per 100 km how much faults are present. Stelometer It makes use of fiber and checks fiber Presselay strength by using formula after taking reading. It consists of a compressor and a scale is attached to it. color grading becomes the crucial factor. These machines use ultraviolet rays. polyester and cotton is changed if new product is made.e. The reading is taken from meter. which pass through the cones. Fibrograph It makes use of a computer to check staple length. a small machine is used to check the color difference by weaving cloth.

they have hired Chaudhry Nazir Company to state the duties of every employee in the mill. it has its distinct importance. they plant it for Gulshan Too. Many of them are very successful for the past decade of 90’s. In every country. In Pakistan.        ISO-9000 The Planning Department previously decided to get ISO-9002 for Gulshan Textiles. The overall performance of this sector of industry has declined due to numerous factors. Few established firms are able to maintain their existence. ISO-9002 is given to the company is the surety that they are performing their function well and providing their customers the best services. But know the company has got the ISO-9002 certificate on 1st January 2000. but “There is never a rainbow without rain. It is basically a spinning unit and is successfully performing its operations for the last 20 years. Preface The textile industry is backbone of Pakistan. After that. which belongs to Gulistan Group. The foreign exchange is dependent on it. but then they switched their attention to Gulistan Textile Mills. there are many small and big firms working in this field.” I tried my level best to make to this report more comprehensive and precise but place of improvement always remains there. This report highlights various operations of Gulshan Textile Mill in detailed and precise maner.   Author . Although this report has given me a tough time. One of them is “Gulshan Textiles”. For this purpose.

Special thanks to: Chaudhry Nisar Ahmad (General Manager) Chaudhry Shakoor (Technical Director) Javad Ahmed   Majid farooq Contents Executive Summary 1 Introduction of the Company 3 Organizational Setup 5 Location 6 Facility Design & Layout 8 . the most Merciful.Acknowledgement All thanks to Allah. let it flow like a river to the ones who have thirst for knowledge. His wisdom to mankind that allows us to meet and help each other to accomplish our required ends through his created means. It is all the will of Allah and His sanctified Pen and the gift of God. I also wish to acknowledge all those people who helped a lot in preparing this report and especially to the people of Mill who never hesitated to provide us any kind of information and knowledge regarding this. I am thankful to our honorable teacher Dr. who think that the individuals must not restrict knowledge. There are some persons. Awan who has given us the opportunity to get practical knowledge about our subject. Hayat M. Beneficent and benevolent. Through our studies all that he’s been teaching us was very helpful in understanding the operations of the firm.

Support Facilities 9 Forecasting 10 Capacity Planning 11 Production Process 12 Production Flow Chart 16 Product Planning 17 Gulshan Textile Mill’s Other Operations 18 Material Requirement Planning 19 Inventory Management 20 Quality Control 22 ISO-9002 25 .